Actuator Cover – Reverse-Engineered from a Photo, 3D Printed & Test-Fitted

Reverse-engineered a replacement cover for an actuator housing, then 3D printed it and test-fitted it on the real part. How it was done: - Scaled a photo of the original cover to measured dimensions and traced the outline - Modelled the four mounting bosses (including a slotted hole), the inner pocket and the raised lip - Checked accuracy by overlaying the finished model on the photo of the original part, so the bosses, holes and edges could be compared directly - 3D printed the cover and test-fitted it on the actuator Modelled in FreeCAD and SOLIDWORKS, with embossed lettering added inside the cover as a custom detail. Images: printed cover beside the original, the original part, the model overlaid on the photo, and the finished CAD model.