Objective
The goal of this project was to create an accurate digital copy (solid model) and, if necessary, a complete set of drawings for the DIAM ML-180/3 diamond drilling rig handle. The primary objective was to enable rapid replacement of broken handles using 3D printing, thereby reducing equipment repair costs and downtime.
Tasks
The work began with 3D scanning of the original, partially worn handle. After obtaining the polygonal mesh (.stl), the main task was to build an accurate parametric solid model in Geomagic Design X. During the reverse engineering process, the original design intent was restored: symmetrical features were aligned, ideal planes and fillets were reconstructed, and defects from service use (chips, scratches) were eliminated. Particular attention was paid to the accuracy of mating surfaces and internal stiffening ribs to ensure correct assembly.
Results
The outcome was a fully parametric solid 3D model of the handle, ready for manufacturing. To verify the geometry, ergonomics, and assembly fit, test prototypes were 3D-printed using ABS plastic (for rigidity) and PETG (for impact resistance). The prototypes fully confirmed the modeling accuracy and their functionality when installed on the equipment. The client received a digital archive that allows a new handle to be manufactured at any time, completely solving the problem of sourcing and waiting for original spare parts.