Reverse Engineering Pinwheel Sprocket

At Engineering Specialties, Inc. (ESI), we pride ourselves on our ability to design and build any part our customers need — no matter how unusual or complex the project. Recently, we were approached by a New England-based security products company to manufacture an aluminum-machined component.
Unfortunately, the requested part — a 1.25 inch thick x 2.375 inch diameter pinwheel sprocket — had become virtually obsolete in recent years; there were no drawings or CAD models available for our team to reference. The customer needed 100 of these parts made with each piece part having several tolerances of +- .002 inches; ESI was determined to deliver them.