Reverse Engineering & 3D Printing

This is a spare lever for the climate control of Ford Fiesta, 2008 onwards, allowing you to switch between the hot and cold settings. The original part is made using injection moulding, the problem however lies in the choice of plastic as the repeated load on a small pin would eventually cause the part to break.

Our client reached out to OrijaDesign with his broken lever asking if we could solve this problem. Redesigning this ford actuator was an exciting project, with our focus being on eliminating the existing flaw and keeping production costs as low as possible.

The new and improved lever was developed in under a week. This was made possible through the use of our 3d printing which allowed us to prototype, test and manufacture in different materials.