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Replacing the glazing clips on a balcony, no longer available after 50 years of UV and sea air — a reverse-engineering job, in ASA for weather resistance.
Our client wanted to replace the clips holding the Plexiglas panes of their balcony in place. The original parts, fitted around fifty years ago, were badly degraded by their constant exposure to wind and sea air. The aim was to restore a reliable fixing while keeping the appearance of the existing system.
With the old clips no longer available, a new version had to be designed to take over their exact function. The future part had to:
Working from an existing clip, we carried out a reverse-engineering exercise to produce a version suited to 3D-printed manufacture. Our goal was to deliver a solution that was:
We studied the existing clip to understand how it worked and the constraints it faced. This analysis allowed us to: record the essential dimensions; take into account the thickness of the Plexiglas panes; identify the constraints linked to sea wind and UV; keep the visual appearance of the original part.
The new clip was designed in three elements: a front part; a rear part; and a seal fitting between the clip and the pane. The assembly is held together with screws to ensure a reliable grip. The parts were made in ASA, a material particularly suited to outdoor applications thanks to its excellent resistance to UV and the weather.
To simplify fitting, the clips were delivered pre-assembled. Each set includes: the complete clip; the seal; the screws fitted. Four clips were made for this first intervention. In time, all 56 clips on the balcony can be replaced gradually as needed.
Thanks to reverse engineering and 3D printing, it is possible to replace parts that have become unavailable without altering the existing installation. By faithfully reproducing the original part, while using a material better suited to today's conditions, this solution extends the life of the installation and makes future replacements easier.
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