The Challenge

A client was unable to find replacement mounting hardware for a specific window blind system, as the original brackets were no longer available for purchase. The small, proprietary parts were complex, featuring precise interlocking snap-fit geometry and a slot for variable screw positioning. Without these brackets, the entire blind assembly was unusable. The challenge was to reverse-engineer a complex, small-scale mechanical part and manufacture it with enough precision to retain all original functionality.

The Solution

The original white bracket was carefully measured and reverse-engineered from scratch. The primary challenge was replicating the internal "snap" fit that holds the blind in place.

The replacements were printed in a high-density grey SLA resin, chosen for its excellent dimensional stability and high resolution, which was essential for getting the mechanical fit right. To optimize production, multiple units were nested on the build plate, allowing for a small batch production run to keep spare parts on hand for future use.

Key Features

Material: High-resolution Grey Resin (SLA)
Application: Functional repair and reverse engineering of obsolete hardware
Engineering: Precision snap-fit replication and integrated screw slot
Method: Digital measurement and Fusion 360 modeling
Scale: Small, complex geometry

The Result

The 3D-printed brackets provide a perfect factory-level fit and finish, restoring the window blinds to full service. By using SLA technology, we successfully replicated the critical tolerances needed for mechanical parts, proving that expensive hardware doesn't need to be scrapped due to the failure of a single, unfindable plastic clip.

Custom Replacement Window Blind Brackets