3D scanning / human factors / non-destructive apparatus modification
Engine 264 foam-panel cover
A scan-derived cover creates a clear physical barrier over an out-of-service foam controller while preserving the electronics and existing pump-panel hardware.
The problem
A real need in a specific operating environment.
Engine 264 entered service as a used reserve engine with an electronic foam controller that was out of service. The controller looked remarkably similar to the electronic water-pump controller beside it, creating a predictable risk that an operator could select the wrong panel during a high-stress incident, particularly when the apparatus was unfamiliar or the operator was working under fatigue.
The application
Designed around how the result would be used.
The department needed an engineering control that made the unavailable foam system unmistakable without removing controls, changing electronics, drilling the pump panel, or preventing future restoration.
The process
Define. Engineer. Validate. Produce.
The manufacturing method followed the requirements of the application, not the other way around.
- 01
Capture the existing controller, faceplate, mounting points, and surrounding pump-panel geometry with a 3D scanner.
- 02
Build a cover in CAD from the scan data so it clears the existing controls and matches the available hardware.
- 03
Integrate high-contrast text and graphics directly into the cover to communicate the system status immediately.
- 04
Add ventilation openings and mount the cover with the panel's existing fasteners so moisture can escape and no permanent apparatus modification is required.
The final product
Error-prevention control.
The installed cover physically blocks access to the out-of-service controller and makes its status obvious at a glance. The foam electronics remain intact behind the cover, existing hardware secures the part, and ventilation helps prevent trapped moisture from affecting the controller.
- Reduces control-selection error risk
- No electronic or permanent panel modification
- Existing hardware and ventilation preserved
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