Sualp Ozel
At AU 2025 The Design & Make Conference, the Autodesk team encountered a unique challenge that showcased the power of collaboration, reverse engineering, and rapid prototyping—all achievable through Autodesk Fusion and Prusa 3D printers.
It began when Frank Wolbertus, Solution Specialist VDC/XR at TBI, an Autodesk customer, faced a critical issue with his wheelchair. A mishap caused a vital part of his wheelchair to break, jeopardizing his mobility during the event. “I knew from previous experiences that somewhere in this expo center, there are always people with 3D printers,” says Frank. “I thought if I could contact somebody, that maybe they could 3D print [a replacement] part for me to solve this.”
As luck would have it, Frank was surrounded by people who see broken parts as an opportunity to innovate. Determined to help, the Fusion team on site knew that leveraging Fusion and Prusa hardware could provide a quick and efficient solution.
Rapid reverse engineering and prototyping
Frank brought the broken part to the Autodesk team, where we immediately began reverse engineering the component using Autodesk Fusion. The process started with precise measurements, and within approximately 30 minutes, we had a detailed digital model ready for prototyping.
We handed off the digital model to the Prusa team, who utilized its 3D printers to create the initial prototype. In about an hour, the first test part was ready. While the part was printing, Frank and one of our team members went to retrieve his wheelchair motor to ensure the newly printed part fit perfectly.
Iterating for perfection
The initial part performed well for a short distance, but it eventually snapped again due to unexpected stresses. This is where Fusion showed its true strength—the ability to quickly iterate and improve designs. We used the insights from the first prototype to make necessary adjustments, and within hours, we had a second-generation component that not only fit perfectly but was sturdy enough to last through the entire event.
The entire process, from identifying the problem to implementing an effective solution, was completed impressively fast. Without the combination of Fusion’s powerful design tools and the rapid manufacturing capabilities of Prusa 3D printers, this success story would have taken days, if not weeks, to unfold.
Frank’s experience at AU 2025 is a testament to the power of innovation and teamwork. The ability to rapidly reverse engineer and prototype crucial components highlights how Autodesk Fusion and Prusa 3D printers are revolutionizing the manufacturing and design process. Both tools made a positive impact on Frank’s conference experience and demonstrated how real-world problems can be resolved swiftly with the right tools and a collaborative spirit. Frank was extremely happy, which was the ultimate goal.
Discover how Prusa can help you design and make quickly and easily here.