Reverse Engineering Design of Compressor Gear

In 2020, Taka Turbo was entrusted by Vale Indonesia Tbk to perform a complete reverse engineering and redesign of a critical compressor gear originally manufactured by Kawasaki Heavy Industry.

This project played an essential role in maintaining the reliability of Vale’s nickel processing plant by ensuring continuous compressor performance and reducing dependency on imported OEM components.

Challenge

The original compressor gear had reached its wear limit and required replacement. However, OEM spare parts were no longer readily available, and lead times from overseas suppliers posed a significant risk to plant uptime.

The gear’s complex geometry and material composition demanded advanced metrology, design accuracy, and strict adherence to mechanical tolerances equivalent to the original specification.

Solution

Taka Turbo’s engineering division conducted comprehensive reverse engineering using advanced 3D scanning, material analysis, and dimensional inspection. The data was reconstructed into a precise 3D CAD model to replicate the original design.

Design validation and finite element analysis (FEA) were performed to ensure load capacity, gear meshing accuracy, and durability. The gear was then manufactured using high-grade alloy steel, followed by precision heat treatment and quality inspection to meet OEM-level performance.

Result

• Successful reproduction of the compressor gear with identical functional performance
• Significant reduction in procurement time and cost
• Enhanced reliability and mechanical integrity of the compressor system
• Strengthened client confidence in Taka Turbo’s local engineering and manufacturing capability

Conclusion

This project showcases Taka Turbo’s advanced engineering capabilities in reverse engineering and precision manufacturing. By delivering OEM-equivalent quality within Indonesia, Taka Turbo supports industrial self-reliance and reinforces its role as a trusted partner in sustaining critical equipment for the mining and energy sectors.