Bull Gear

Project Overview

A client operating a legacy ball mill contacted our firm with an urgent need to replace a critical component — the main Bull Gear. The original equipment manufacturer (OEM) specifications, drawings, and part numbers were no longer available, making direct replacement impossible through standard channels.

Scope of Work

Faced with minimal reference data and aging equipment, our team executed a full reverse engineering initiative, starting with an on-site evaluation of the existing gear.

• Field Assessment & Data Collection:Our team visited the site to perform detailed manual measurements and conduct 3D scanning of the existing Bull Gear, despite the lack of OEM documentation.

• 3D Modelling & Technical Design:Using the captured data, we developed a high-fidelity 3D model of the gear, recreating the geometry and features necessary for accurate replication and performance matching.

• Manufacturing Support:From the 3D model, we produced complete manufacturing drawings and documentation, which were issued to trusted partner foundries. These foundries used our deliverables to successfully pour and produce the replacement Bull Gear.

• Delivery & Client Support:The new gear was manufactured and supplied to the client, restoring functionality to their ball mill with minimal downtime and without OEM involvement.

  
  

Outcome

This project highlights our ability to solve complex engineering challenges in the absence of original design data. By combining site expertise, digital modelling, and strong manufacturing partnerships, we delivered a fully functional legacy replacement part — ensuring operational continuity for the client and extending the life of their equipment.