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// 16
RefIE-016
ClientRafał (prywatny)
Year2025
Scale1:1
[Reverse Engineering][Mechanical][3D Print]

Reverse-engineered service block for a FOX suspension

A service block (adapter) for a FOX suspension, reverse-engineered from the geometry of the original component, together with a matching bushing. The body is printed in carbon-fibre reinforced PETG-CF with a PETG orange accent, two-colour on a Bambu Lab X1C. 5 perimeter walls, 15% infill, 0.2 mm layers, 0.4 mm nozzle. The logo is embossed directly into the body. The part was test-fitted.

Service block for a FOX suspension, perspective render with an extra pin and the orange PETG logoIE-016 · FIG.01 · Service block for a FOX suspension, perspective render with an extra pin and the orange PETG logo

Problem

There is no off-the-shelf part for servicing this specific FOX suspension. The geometry and contact points had to be reconstructed from the existing component so the block would hold the assembly securely during servicing, without damaging it. The part also had to be stiff and durable, which is why a carbon-fibre reinforced material was chosen.

Outcome

A working service block with a matching bushing, reconstructed without any manufacturer files and printed in carbon-fibre reinforced PETG-CF. The part fits the FOX suspension interface and is ready for servicing. It belongs to a broader set of bike parts made for this client.

  1. 01Measuring and reverse-engineering the FOX suspension interface from the physical part: outline, working seat and contact points.
  2. 02CAD modelling of the service block and the matching bushing, with the logo embossed directly into the body.
  3. 03Material and print strategy: a PETG-CF (carbon fibre) body for stiffness, a PETG accent, two-colour printing on a Bambu Lab X1C. 5 perimeter walls, 15% infill, 0.2 mm layers.
  4. 04Printing on our own printer farm, fitting against the part, and delivering the set (block plus bushing).

Specifications

IE-016
Part
Service block + bushing
Method
Reverse engineering
Material
PETG-CF + PETG, 2 colours
Print
Bambu Lab X1C, 0.4 mm nozzle, 0.2 mm layer
Build
5 walls, 15% infill
Finish
Logo embossed into the body
Top view: the embossed FOX mark, the working seat and a mounting hole
FIG.02Top view: the embossed FOX mark, the working seat and a mounting hole
The bushing matched to the service block, printed separately in PETG-CF
FIG.03The bushing matched to the service block, printed separately in PETG-CF
A set of bike service parts prepared for printing
FIG.04A set of bike service parts prepared for printing
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