Reviving Vintage Iron: 3D Scanning and Printing an Avery Steam Engine Smoke Box Door

Hello, vintage machinery aficionados! Welcome back to Vintage Parts Revival, where we blend cutting-edge technology with historical preservation to breathe new life into antique agricultural equipment. Today, we're diving into a project that's close to our hearts: recreating the iconic smoke box door from an Avery Company steam engine. Known for their robust undermount designs, Avery engines from Peoria, Illinois, featured a snarling bulldog mascot on the smoke box door, complete with the slogan "Teeth Talk" – a symbol of the company's tough, reliable machinery that powered farms across America in the early 20th century.

The smoke box door isn't just a functional component; it's a piece of art that seals the front of the boiler. It allows access for cleaning ash and soot while showcasing Avery's branding. Originals are rare and often worn from decades of use. So when we got our hands on a well-preserved example from a 1910s-era traction engine, we knew it was prime for digital revival. Using 3D scanning, CAD modeling, and high-resolution 3D printing, we recreated it with astonishing fidelity. This post highlights how modern tools capture and reproduce intricate details like the bulldog's fierce expression, textured fur, and embossed lettering.

Let's break down the process step by step!

Step 1: 3D Scanning the Original Artifact

Our journey began with the original smoke box door, mounted on a restored Avery steam engine in a dimly lit barn workshop. This cast iron piece measures about 18 inches in diameter and weighs around 40 pounds. It bears the marks of history: slight pitting from corrosion, but the bulldog emblem and gold lettering remain remarkably intact.

To digitize it, we employed a good quality 3D scanner. The scanning process was non-contact and non-destructive, ideal for delicate antiques. Here's how it went:

• Preparation: We gently cleaned the surface to remove loose debris, ensuring no alterations to the patina. The scanner's built-in lights helped illuminate the dark cast iron.

• Capture: Multiple passes were made around the door, focusing on high-detail areas like the bulldog's teeth, whiskers, and the raised "AVERY CO. PEORIA ILL. 1793" inscription. The scanner operates at a resolution of 0.02mm (1/1270"), picking up subtle textures such as the fur on the bulldog's back and the grainy surface from the original sand casting.

• Data Processing: The resulting point cloud was meshed in real-time, creating a watertight 3D model with over 7 million polygons. What impressed us most was the scanner's ability to capture fine details – even the tiny cracks in the paint and the depth of the bulldog's growl were rendered perfectly.

  
  

Check out this photo of the scanning in action: we carefully orbit the door with the handheld scanner, its blue laser projecting structured patterns to map every contour.

In field 3D scanning

This step took about an hour, yielding a digital twin that preserved the door's authenticity down to the micron level.

Step 2: CAD Modeling for Precision and Refinement

With the scan data imported into CAD software, the real engineering began. The raw mesh was detailed but noisy from surface imperfections, so we refined it into a production-ready model.

Key tasks included:

• Mesh Cleanup: Smoothing out artifacts while retaining critical features. For instance, the bulldog's eyes and collar were isolated and enhanced to ensure sharpness.

• Parametric Conversion: We traced profiles of the door's circular flange, hinges, and latch, then extruded and revolved them into solid bodies. This allowed for scalability – we could resize for full-scale replicas or miniatures.

• Detail Enhancement: The scanner had captured the embossed lettering so well that we could vectorize it directly. We added subtle draft angles for printability and ensured the model accounted for material shrinkage if cast later.

• Simulation and Testing: Virtual assembly tested the door's fit on a digitized engine model, confirming the hinge alignment and seal integrity.

  
  

The CAD phase showcased the scanner's prowess: details like the bulldog's individual teeth and the dotted border around the emblem were so precise that no manual sculpting was needed – it was all from the scan!

Final design from CAD modeling, ready for print

Step 3: 3D Printing the Replica – Detail in Every Layer

Now for the magic: bringing the digital model back to physical form with 3D printing. We opted for an extrusion FDM machine to print the part with PLA plastic – perfect for replicating the intricate details.

• Material Choice: We used a durable PLA to mimic cast iron's look. With multi-material technology, we were able to replicate the colors of the original piece without using any paint.

• Printing Process: The model was oriented face-up to minimize supports on detailed areas. Print time was about 8 hours for a scaled-down version (6-inch diameter for display).

• Post-Processing: Supports were removed carefully. A replica where you can feel the bulldog's fur ridges and read the crisp "Teeth Talk" slogan without magnification.

  
  

Our printers excelled here, reproducing the scanner's captured details flawlessly. The bulldog's menacing grin, complete with every tooth and whisker, pops out just like on the original. Even the subtle casting marks from over a century ago were preserved, making this replica indistinguishable from an antique at first glance.

Here's the finished 3D printed replica, held up for inspection – notice how the fine details shine through, from the latch ring to the embossed mascot.

Scaled down print model in color

The Importance of Preservation

Preserving history isn't just about keeping old machines running; it's about honoring the craftsmanship and stories behind them. Each piece we restore or recreate tells a tale of innovation and hard work. The Avery smoke box door is no exception. It represents a time when steam power was king, and every component was made with care.

By using modern technology, we can ensure that these stories live on. The ability to recreate parts like the smoke box door means that enthusiasts can keep their machines in top shape, preserving the legacy for future generations.

Conclusion: Preserving History, One Scan at a Time

This project exemplifies how 3D technology bridges the past and present. By scanning the Avery smoke box door, we captured details that would be impossible to replicate by hand – the bulldog's textured coat, precise lettering curves, and even historical wear patterns. Our 3D printers then turned that data into tangible pieces, ready for restoration projects, museum displays, or enthusiast collections.

If you're restoring steam-era tech, reach out – we can scan and print custom parts for you!

What vintage part should we revive next? Share your ideas in the comments. Stay tuned for more revivals!

Posted on August 3, 2025