Alexander S.

I specialize in Reverse Engineering and Product Design of plastic parts for injection molding, with 15+ years of hands-on engineering and manufacturing experience.

I help clients turn existing parts, physical samples, drawings, 3D scans, or ideas into accurate, manufacturable plastic products ready for injection molding.

My main focus is plastic product development, especially when the goal is to create a practical design that can actually be manufactured—not just a good-looking CAD model.

What I can do for your project
- Reverse engineering of existing plastic parts and physical samples
- Recreating parts from measurements, photos, drawings, or master models
- 3D CAD modeling of plastic components
- Product development based on customer requirements
- Modification and redesign of existing plastic parts
- Design optimization for injection molding (DFM)
- Wall thickness, draft angles, ribs, bosses, parting lines, and other molding considerations
- Preparation of models and documentation for manufacturing
- Development of simple, cost-effective mold concepts for small production runs

My practical advantage

I have spent 15+ years working not only with CAD and mold design, but also with actual mold manufacturing and injection molding.

I have personally worked through the complete process:

Reverse Engineering → Product Design → Mold Design → Manufacturing → CNC Machining → Mold Assembly → Injection Molding

Because of this hands-on experience, I understand the practical limitations and costs involved in turning a CAD model into a real plastic part.

For projects requiring small production quantities, I can also develop simplified and cost-effective mold solutions using combinations of aluminum (duralumin) and steel, avoiding unnecessary complexity and manufacturing costs.

This makes me particularly useful for prototypes, small batches, product development, replacement parts, legacy components, and projects where a conventional production mold would be unnecessarily expensive.

Typical projects
- Reverse engineering of an existing plastic component
- Converting a physical prototype into a manufacturable 3D model
- Redesigning an existing part for injection molding
- Developing a new plastic product from customer requirements
- Preparing a plastic part for low-volume injection molding
- Designing a simple, low-cost mold for small production runs
- Improving an existing design to reduce manufacturing complexity and cost

If you have a physical part, sample, drawing, scan, 3D model, or simply an idea for a plastic product, I can help turn it into a practical, manufacturable design.