Precision Die Positioning Ring

This project involved the reverse engineering and manufacturing of a precision positioning ring used for aluminum extrusion dies. The component is mounted on the cassette and serves as a reference element to accurately locate the die assembly during the extrusion process, helping improve pressing efficiency and protect the tooling from misalignment. The main challenge was that the original part was heavily worn, making dimensional recovery difficult. Since even a small positional error could shift the die location and affect the extrusion process, high geometric accuracy was required, especially for the multiple locating holes distributed around the ring. The workflow started with 3D scanning using a Creaform Handy SCAN, followed by reverse engineering and CAD reconstruction based on the best-preserved features of the original component. A fully parametric model was then developed in SOLIDWORKS, ensuring accurate positioning and manufacturability. After design validation, CNC machining toolpaths were prepared using PowerMill. The part was manufactured, inspected, and verified against the required tolerances. To achieve the required wear resistance, the component underwent heat treatment to increase surface hardness before the final finishing operations were completed. Outcome: A high-precision positioning ring capable of accurately locating extrusion dies, improving process consistency, reducing tooling wear, and increasing overall production reliability.