Reverse Engineering a Twix Production Line Part for Mars

Project Overview

We partnered with Mars Incorporated to reverse engineer a critically endangered component on their assembly line: the custom spoon responsible for pushing caramel directly onto the Twix cookie.

Engineering & Execution

Our team conducted high-resolution 3D metrology scanning on the existing worn piece to capture its complex geometry. Using a blend of organic and parametric design software in Rhino and Fusion 360, we optimized the point cloud, reduced the polygon count, and generated a clean, 3D-printable CAD file. Once the digital blueprint was validated, we guided the tooling setup and injection molding process to fabricate production replacements.

Results & Operational Impact

Beyond saving the Twix production line from machinery downtime, subsequent engineering revisions to the part reduced Mars' scrap rate by 80%.

Key Technical Deliverables

• High-precision 3D scanning of legacy, high-wear manufacturing tooling.

• Organic-to-parametric mesh optimization and polygon reduction.

• Tooling consultation and injection molding transition.

• 80% reduction in line scrap rate through ongoing design iterations.

Related capability: Reverse Engineering