How a Manufacturer Reclaimed Control with Reverse Engineered Aluminum Partsby Copper and Brass Sales

Case Study Summary

PROBLEM

A long-time customer of Copper and Brass Sales was experiencing difficulties with an aluminum tooling supplier. Poor service, long lead times, and inadequate packaging were slowing their operations. Locked into a long-standing relationship with a laser cutting vendor, and without CAD files, they had limited flexibility to make a change.

SOLUTION

Copper and Brass Sales provided a smarter, streamlined approach: reverse engineering the parts, digitizing them into CAD drawings, and producing them in-house with waterjet cutting and laser etching services. This solution delivered faster lead times, improved packaging, and a stronger, more reliable partnership.

Introduction: A Legacy Manufacturer with a New Challenge

This California-based manufacturer of pool equipment repair and replacement parts manages a large catalogue of products with a lean but highly skilled team. The company has worked with Copper and Brass Sales for many years, sourcing brass bar stock for hardware components across their product lines. During a recent facility visit, however, our team identified a new opportunity to add value and help them overcome a growing challenge.

The Problem: Supplier Service Issues and Lack of Part Drawings 

While touring the facility, our team noticed a box of aluminum tools. Curious about their use, we learned that the parts were cut by an external laser cutting vendor. Over time, the customer grew increasingly dissatisfied with that supplier’s performance:

• Lead times had worsened
• Packaging was inadequate
• They didn’t feel like a priority customer

Despite these issues, making a switch wasn’t straightforward. After years of relying on the same vendor, the customer no longer had formal part drawings. Without CAD files or prints, their options for change were severely limited. The customer needed a reliable, flexible, and technically capable partner who could help them regain control over their parts without interrupting operations.

Our Solution: Reverse Engineering and Waterjet Precision

Copper and Brass Sales partnered with the customer to develop a long-term, scalable solution that restored both efficiency and confidence. Leveraging our technical expertise and advanced in-house processing capabilities, we proposed a new approach built on reverse engineering, digital standardization, and precision waterjet cutting capabilities.

Reverse Engineering Physical Samples

With no existing prints or CAD files, our team began by collecting physical samples of the aluminum tools from the customer’s facility. At our Fresno location, our engineers used these samples to perform detailed dimensional analysis and create precise CAD drawings.

This reverse engineering process not only replicated the original parts with high accuracy but also allowed us to document critical design features for future use. By digitizing the components, the customer gained permanent, standardized part drawings: a valuable resource that ensured repeatability and design control moving forward.

Precision Waterjet Cutting with 6061 Aluminum

Once the CAD models were complete, production transitioned to our advanced waterjet cutting systems. Using 6061 aluminum plate, our technicians produced the tools with tight tolerances, smooth edge finishes, and exceptional dimensional accuracy.

Waterjet technology offered key advantages for this project:

• No heat-affected zones that could alter the material’s structure.
• Clean, burr-free edges that reduced post-processing time.
• Superior material utilization, minimizing waste and cost.

The result was a durable, high-performance tool ready for immediate use, produced entirely in-house for greater reliability and control.

Enhanced Traceability with Laser Etching

To further enhance quality and usability, each finished tool was laser-etched with the customer’s company name and unique part numbers. This step not only improved internal traceability but also created a professional, branded appearance that supports easy identification in storage and during use. The permanent markings ensure that tools remain traceable through every stage of production and deployment.

Rapid Turnaround and Improved Packaging

The new process not only delivered technical precision but also improved logistical performance. Once part numbers were cataloged and CAD files finalized, orders could be fulfilled with minimal effort. The customer now simply provides a part number and quantity, and Copper and Brass Sales handles the rest, from cutting and etching to packaging and delivery.

Lead times have been reduced to as little as one to two weeks, compared to much longer turnaround times with the previous supplier. In addition, we implemented upgraded packaging protocols to ensure consistent, damage-free delivery, an improvement that eliminated one of the customer’s major frustrations.

The Result: A Trusted Partner for Long-Term Growth

Since transitioning production to Copper and Brass Sales, the manufacturer has experienced measurable gains across multiple areas of performance:

• Significantly Reduced Lead Times: Reliable in-house production enables faster turnaround and fewer production delays.
• Consistent, High-Quality Packaging: Enhanced protection ensures that every part arrives ready for immediate use.
• Professional, Laser-Etched Components: Improved traceability and a polished, branded finish.
• Restored Flexibility and Control: Digital part files and standardized production empower the customer to expand and adapt with ease.

The success of this collaboration has sparked additional reverse-engineering projects as we continue to bring more of the customer’s legacy parts into production. Together, we’re helping them scale their operations, safeguard product quality, and strengthen supply chain resilience for the future.

Facing Similar Challenges? Let’s Talk.

If you’re managing aging tooling, struggling with unreliable suppliers, or simply looking to streamline your manufacturing supply chain, we can help.

Copper and Brass Sales combines waterjet cutting technology and personalized services to help manufacturers solve complex sourcing problems. We’ll work with you to produce components quickly and deliver solutions that increase reliability and speed.

Let us help you reclaim control over your parts production without sacrificing time or quality.
 

Contact us today to learn how we can support your operations with smarter materials solutions.