Replacement PartPETGNext day

Washing Machine Door Latch

A discontinued door latch clip was stopping a perfectly good washing machine from working. We reverse-engineered the original and printed a replacement that's been going strong ever since.

Outcome

Total cost

£12

Customer saved

~£600

Saved from landfill

The problem

A £600 machine, broken by a 5p clip

The customer's washing machine had stopped locking properly mid-cycle. The manufacturer confirmed the part was discontinued — and quoted £180 for a service call that might not even fix it.

The culprit was a small plastic latch clip inside the door mechanism. It had cracked along a stress point, probably from years of use. The machine itself was in perfect working order.

The problem: A £600 machine, broken by a 5p clip

The design

Measured, modelled, tested

The customer sent us the broken part along with a few photos of the door mechanism. We measured the original carefully — including the flex points and clip geometry — and built a CAD model from scratch.

We chose PETG for the print: tougher than PLA, more heat-resistant, and with enough flex to survive repeated door closures without becoming brittle.

The design process: Measured, modelled, tested

The solution

Back in service the next day

We printed two copies — one to fit immediately, one as a spare. Total cost: £12. The customer fitted it themselves in about ten minutes with a screwdriver.

That was eight months ago. The machine is still running fine.

The solution: Back in service the next day

ApplianceReplacement PartPETGReverse Engineering

Washing Machine Door Latch Workshop Drill Bit Holder

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Replacement PartASA2 days

Caravan Corner Trim Clip

An older caravan had lost several of its exterior corner trim clips — no longer made, impossible to source. We printed a batch of 20 in UV-stable ASA so they'd survive years outdoors.

Outcome

Total cost

£38 for 20 clips

Customer saved

Full van refurb cost

UV-stable for outdoor use

The problem

Clips that no longer exist

The owner of a 2003 touring caravan had been trying to source replacement corner trim clips for over a year. The manufacturer had closed, and no aftermarket supplier stocked them.

Without the clips, the trim was lifting at the corners — letting in moisture and making the van look tatty. He needed 20 clips to do the whole van properly.

The design

Designed for outdoors

The customer sent us one surviving original clip and a set of measurements. We modelled it with slightly thicker walls than the original — the old ones had clearly been made as cheaply as possible.

Material choice was important here. Standard PLA would go brittle and fade in UV. We used ASA — the same material used in outdoor automotive parts — which handles sun, rain and temperature swings without degrading.

The design process: Designed for outdoors

The solution

20 clips, ready in two days

We printed a test clip first and asked the customer to check the fit before we ran the full batch. It fitted perfectly, so we printed all 20 and posted them the same afternoon.

The customer fitted them over a weekend. The trim is now secure, the van looks smart again, and he's got a few spares for the future.