Design of complex tools and spare parts
At INFINITIA, we offer a complex tooling and spare parts design service in response to a critical need in industry: the precise adaptation of tools and components to each customer’s specific production processes.
This service is essential when components are required that cannot be purchased on the conventional market, whether because of their technical complexity, particular operating conditions or the need for integration into existing equipment.
Our industrial laboratory has a team specialising in product engineering and CAD/CAM design. It uses the latest simulation, prototyping and manufacturing technologies to develop fully customised, robust and efficient solutions.
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What does complex tooling and spare parts design involve?
What is it?
The design of complex tooling and spare parts involves creating tools, auxiliary devices or spare parts whose specific geometry, critical function or demanding precision requirements prevent them from being manufactured using standard methods.
At INFINITIA, we approach these projects using a methodology that combines reverse engineering, materials characterisation, structural simulation and functional validation. We can start with a damaged component, incomplete drawings or even an operational need that has not yet been precisely defined.
Through mechanical, thermal or wear analysis, we accurately dimension the design to ensure that every tool or spare part integrates seamlessly into its operating environment.
The design of complex tools and spare parts in INFINITIA
INFINITIA stands out for its multidisciplinary approach to complex tooling and spare parts design. Our team combines expertise in materials, mechanical design and experimental validation to ensure that each solution exceeds the customer’s requirements.
We have advanced 3D design tools, finite element simulation (FEM), rapid prototyping systems and mechanical and thermal testing equipment. In addition, we work closely with our customers throughout the entire process, from the initial technical specification to final integration at the plant.
This close collaboration and flexibility allow us to undertake both existing-part redesign projects and the creation of entirely new tooling adapted to specific production conditions.
Advantages of complex tooling and spare parts design
Benefits
One of this service’s main benefits is the ability to reduce downtime on production lines and extend equipment service life by replacing or improving critical parts.
At INFINITIA, for example, we have helped companies redesign tooling that suffered from premature fatigue failures, thereby increasing its durability.
We have also developed obsolete spare parts for industrial machinery using reverse engineering techniques, allowing our customers to avoid costly equipment replacement processes.
Our focus on functionality, reliability and adaptability delivers value at every stage of the product life cycle.
Types of Complex Tooling and Spare Parts Design
types
At INFINITIA, we develop design solutions for complex tooling and spare parts that require a high degree of customisation, precision and adaptation to the customer’s industrial environment. We approach each project through detailed engineering, combining 3D CAD design tools, mechanical simulation and functional validation.
The main types of tooling and spare parts we design in our industrial laboratory are described below.
Positioning and assembly tools
These tools are used to secure, align and assemble parts during production processes, ensuring repeatability and compliance with the required tolerances. Their design is adapted to the component, the required fastening system (mechanical, pneumatic or magnetic) and the operating conditions.
In INFINITIA we develop tools for assembly lines that optimize operating times and reduce the appearance of dimensional defects.
Obsolete or commercially unavailable industrial spare parts
We design industrial spare parts from physical samples or incomplete drawings using reverse engineering techniques. We combine materials characterisation, 3D scanning and functional analysis to reproduce or improve critical components.
For example, we have redesigned gears for industrial machinery incorporating improvements in materials and surface treatments to increase their service life.
Tools for testing and validation of components
We manufacture specific test fixtures that ensure parts are correctly secured during mechanical, thermal or functional tests. These devices ensure uniform load transfer and high repeatability of results.
These include gripping fixtures for fatigue testing plastic components, custom-designed to match the geometry of each part.
Tools for thermal and curing processes
We design structures and supports intended to fix parts during curing, drying and heat treatment processes. These tools are prepared to withstand demanding conditions of temperature, pressure or controlled atmospheres.
In a recent project we developed metal frames for the curing of components made of composite materials, ensuring their stability throughout the process.
Functional spare parts optimised through redesign
We redesign industrial components to improve their mechanical strength, reduce their weight, facilitate their manufacture or adapt them to new operating conditions.
We use finite element simulations (FEM) to validate the modifications and select the most suitable materials. A representative example was the redesign of a structural support replaced by a machined version of aluminum with superior performance.
Applications of complex tooling and spare parts design
Sectors
The design of complex tooling and spare parts has a cross-sector impact across many industrial sectors. At INFINITIA, we help our customers solve technical challenges, improve process efficiency and reduce their dependence on external suppliers.
Automotive industry
In automotive applications, precision and repeatability are essential. We design tooling for welding, positioning and component assembly, as well as spare parts to replace discontinued critical components.
- Development of Fastening tools for Dimensional inspection of Plastic parts.
- Metal spare parts design for Test banks.
- Manufacture of tooling resistant to wear.
Industrial Machinery Sector
Many critical machines operate with components that are no longer commercially available or must be adapted to new conditions. At INFINITIA, we redesign these spare parts to ensure operational continuity.
- Reverse engineering of components subject to fatigue loads.
- Optimisation of parts subject to abrasive wear.
- Incorporation of design improvements to facilitate maintenance and assembly.
Home appliances and consumer goods
We design tooling for product testing under simulated use conditions, ensuring real-world performance. We also develop spare parts with new functionalities.
- Supports and fixtures for testing plastic components.
- Redesign of levers and joints to improve strength.
- Manufacturing of tools for Repetitive load tests.
Energy Sector
In electrical and electronic applications, tooling and components must withstand high-temperature environments and electrical voltage. INFINITIA develops solutions that combine insulation, strength and complex geometry.
- Fastening elements made from technical polymers with low electrical conductivity.
- Support elements adapted to requirements of Insulation and resistance to thermal aging.
- Spare parts prepared with Materials tested under specific regulations to ensure reliability.
Food and pharmaceutical industries
We design tooling and functional components that comply with hygiene regulations. We use materials suitable for different use cases and geometries designed for easy cleaning and disassembly.
- Nozzles and diffusers for dosing systems, optimized for certain processes.
- Tooling for in-line positioning.
- Hygienic design of 3D-printed parts for easier cleaning.
Complex tooling and spare parts design to improve industrial competitiveness
Value
The design of complex tooling and spare parts is an essential service for industrial companies seeking to maintain, optimise or evolve their production processes. Access to tailor-made solutions for both tools and components makes it possible to reduce downtime, improve operational efficiency and extend the service life of existing equipment. In sectors where standard spare parts are scarce or a high degree of customisation is required, this type of technical design becomes a strategic advantage.
At INFINITIA, we have the experience, multidisciplinary expertise and technological infrastructure required to carry out these developments with rigour and precision. Our projects combine CAD design, structural simulation, material selection, functional validation and prototype manufacturing, ensuring maximum adaptability to each customer’s environment and specific operating conditions.
In addition, we anticipate potential failures or inefficiencies through structural analyses and validation under real-world conditions, allowing us to deliver optimised solutions from the outset. This comprehensive approach, focused on product functionality and reliability, positions INFINITIA as a key technology partner for industries operating under highly demanding standards.
The constant evolution of industrial processes, together with advances in technologies such as additive manufacturing, high-precision machining and design digitisation, creates new opportunities for innovation in tooling and spare parts design. At INFINITIA, we are ready to support our customers on this journey by developing solutions that not only solve a specific problem, but also generate long-term value in their processes.
