Selected projects.

A sorting grapple was fully designed for a Terex TW85 wheeled excavator. Bolted and pinned joints were sized using analytical calculations, while the frame, connecting link and grapple jaws were analysed and optimised using the finite element method (FEM).

A custom-developed Python program supported the design of the closing mechanism and the positioning of the pivot points. A movable, functional scale model was also produced using SLA 3D printing at a scale of 1:12.

A ripper tooth was designed for a Terex TW85 wheeled excavator to loosen roots and heavily compacted soil. S235 structural steel was specified as the material.

The manufacturing documentation included individual part drawings, welding drawings and DXF files for plasma cutting the required profiles.

A broken gear lever cap with an M48 × 1.5 internal thread was reverse-engineered from the original part for a 1962 Multicar M21 and manufactured using SLA 3D printing.

A second version with a 36 mm hexagon across flats makes installation easier. A spacer washer was also adapted and produced from flexible plastic using FDM 3D printing.

An additional air intake was developed for the air filter housing of the Simson S50 and S51 to increase the intake opening. The part fits securely into the prepared opening.

A filter mat can be placed between the two components. The part was manufactured using SLA 3D printing with tough black resin.

Several teeth on the plastic gears of a remote-controlled Siku tractor at 1:32 scale were damaged. The affected components were recreated in CAD to restore the drive mechanism.

The gears were manufactured using SLA 3D printing with black, ABS-like resin. The original slip clutch was omitted, and the larger gear was mounted directly onto the output shaft.

A compact replacement ball stud was designed for damaged linkage components of vehicle level sensors, featuring an M5 internal thread, an M6 external thread and a 10 mm hexagon across flats.

Two ball studs can be connected using a standard threaded rod to create an adjustable linkage. The parts were manufactured using SLA 3D printing with tough black resin.

A flexible washer protects the paintwork on the side cover of a Simson S51. Its dimensions are 6 mm inner diameter, 24 mm outer diameter and 1 mm thickness.

The part was manufactured using FDM 3D printing from a durable, rubber-like plastic. Its geometry and dimensions can be adapted for other applications.

During a windscreen replacement on a 1992 Opel Monterey, the original mounting clips were damaged. Suitable replacement parts were needed to install the new windscreen.

The clips were reverse-engineered in CAD from the original parts and manufactured using SLA 3D printing with ABS-like resin – in white to match the originals and in black as an alternative for comparison.

The rubber cover over a button on a car key was damaged, while the key and its electronics were still fully functional.

A precisely fitting replacement cover was produced from flexible plastic using FDM 3D printing. After installation, it was bonded to the existing housing around its perimeter.

A missing storage compartment insert was recreated for a VW Golf 5 centre console, which is also used in the VW Jetta 5.

The geometry was adapted in CAD to fit the existing opening. The insert was manufactured using FDM 3D printing with matte black PLA for a discreet fit into the vehicle interior.

Where the ignition key passes through the side cover of a Simson, direct contact can damage the paintwork around the opening.

A precisely fitting insert protects the edge of the opening and blends discreetly into its contours. It was manufactured from black flexible plastic using FDM 3D printing.

Because the window extends all the way to the adjacent walls on both sides, conventional side-mounted curtain rod brackets could not be installed.

Custom wall brackets were developed with a central screw fixing and a form-fitting rod holder. The brackets were manufactured using FDM 3D printing with matte black PLA.

Following a modification, the 16 mm opening for the rev counter drive on a Simson S51 engine housing needed to be sealed.

A precisely fitting sealing plug was developed from flexible, durable plastic and manufactured in black using FDM 3D printing.

The ceiling power outlet was not located where the light fixture was intended to be installed, leaving part of the cable exposed.

A cable cover was designed to conceal the wiring and visually match the light fixture. The part was manufactured using FDM 3D printing with matte black PLA.

A custom-fitting cover with an integrated chicken motif was created for an unused pipe opening measuring 170 mm in diameter.

The geometry was developed in CAD. The motif was prepared with the help of AI image generation and incorporated into the model. The part was manufactured using FDM 3D printing with matte black PLA.