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Reverse Engineering Services for Manufacturer of Refrigeration Compressors

Case Study on Reverse Engineering Services

The Client

Our client is a manufacturer and supplier of spare parts for a wide range of refrigeration compressors throughout the UK, Europe and Middle East.

Situation - Business Needs

The client had a specific need of carrying out reverse engineering on fiber gaskets so as to derive solid models in DXF AutoCAD file format. The business need resulted from issues like dearth of skilled resources and budgetary limitations. The client decided to garner and examine offshore possibilities to leverage on the cost advantage from an offshore solution, given that order volumes were significantly high. It also wanted to capitalize on the competency of an outsourcing vendor to streamline its operations and achieve greater efficiency.

The client's business situation entailed -

  • Reverse engineering of hundreds of gaskets according to predefined specifications
  • Shipping the gaskets to an offshore location
  • Deriving error-free true dimensional DXF output of each gasket
  • Using the DXF files to set up shapes needed to cut the gaskets to precision


Some of the key challenges faced during the course of the project were -

  • The gaskets came in various shapes and sizes - adding to the complexity of the job
  • Measuring, analyzing and testing each gasket design meticulously to preserve design intent
  • Providing a true dimensional DXF file accurate to the original in an editable electronic format
  • Working within the budgetary constraints and a stipulated time frame set by the client

The Outsource2india Solution

The project team did a thorough requirement analysis to decide on its approach to the project. The notable components of The Outsource2india Solution included -

  • Laser scanning of a few sample gaskets to get the cloud point data
  • Extracting drawings from the data
  • Converting the scans to DXF files using SOLIDWORKS 2012
  • Getting the samples reviewed and approved
  • Starting work on full order quantity- 500 gaskets- after the client was satisfied with the quality of the samples
  • Using state-of-the-art workstations complete with AutoCAD, SOLIDWORKS and other software
  • Setting aside resources in the form of back up staff and funds to meet project deadlines
  • Deploying backup and disaster recovery systems to prevent downtime
  • Ensuring top-level security of client data by employing rigorous security measures that included -
    • Secure VPN communication - IPSec/PPTP for secure access to files and information
    • McAfee Enterprise Suite for virus prevention and cure
    • HIPS (Host Intrusion Prevention System) and NAC (Network Access Control)
    • Gateway level anti-spyware and spam filter for internet access and mail server
    • URL filter application for surf control
    • Domain level access restrictions along the line of Group Policy
    • Restricted Internet Access based on Domain Authentication
    • Centralized server based storage and File system access policy based in user authentication.


  • The client experienced savings to the extent of 50%
  • Freed up resources and overheads associated with hiring additional staff, and helped the client focus on its core business goals
  • Our solution enabled the streamlining of manufacturing processes resulting in better efficiency
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CAD Conversion 2D Drafting 3D Modeling
  • O2I's Mechanical Engineering team functioned as an extended team for an oil & gas company. We helped them complete the project in record time, resulting in substantial time and cost savings.
  • Our FEA Services team has successfully completed FE Analysis and assisted in validation and certification of equipment used in offshore applications.
  • O2I's Mechanical Engineering team is involved in updating the current database of drawings in different CAD platforms and converting the same to a common CAD platform for a client.
  • O2I's Mechanical Engineering team is working on creation of 2D CAD drawings for a large European food and beverage industry.
  • We are providing Virtual Assistant services for Engineers and Consultants, supporting the in-house Engineering team in gathering Engineering Data for a large mass lift company.
  • Our Engineering team is providing tool design assistance to a large shipping company.
  • We are assisting a precision component manufacturer to convert large volumes of hand sketches to editable CAD files.
  • Our Mechanical Engineering team is assisting a food and beverage company with re-engineering existing machinery and finding better design alternatives.
  • The Mechanical 3D Product Animation team provided a scope break-up for 180 seconds of animation for an engineering consultancy & contracting company.
  • Our CAD services team is providing design and documentation solution to a large precision component manufacturer in the Europe.
  • Our Engineering team is currently executing a Reverse Engineering project for high precision components at our facilities.
  • The Engineering team is involved in concept design of mass lifting components for a large shipping company.
  • Our Mechanical Engineers completed a CAD conversion project for a large consulting firm in record time while also ensuring the highest quality.
  • Our Engineers and styling experts are working on providing assistance to our client in restoring vintage vehicles.
  • The Mechanical Engineering team is updating 3D models and conversion of the same models to different modeling platforms for an F&B company.
  • Our team is helping an automotive company to customize product display of automotive components.
  • The Engineering team at O2I is executing concept design of equipment used in the agricultural industries.
  • We are assisting a large aerospace company in converting a large number of hand sketches to CAD drawings.

Our Clients

  • Alcon
  • Redwood E-Learning Systems
    Yale School of Management
  • Loomis
    Data Infinity
    Auto MiddleEast
  • Camnet
  • Eraid
    Financial Planning Association of Australia
  • International Career Institute
    Carole Holding
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