MIDDLESYS CORPStart a project
MIDDLESYS case files

Real parts, real constraints, real deliveries.

A look inside recent projects — how obsolete assemblies, one-off covers, custom tools, and unusual commissions moved from problem to physical answer.

Original battery tray base and cover laid out beside the 3D-printed replacement components
Test & measurementSLA

The Last Battery Tray: Reverse Engineering an Obsolete Assembly

An overseas supplier discontinued a critical battery tray assembly, and exactly one unit remained. We reverse-engineered it and delivered 200 end-use replacements.

Read case file
More from the shop floor03 case files
Black 3D-printed HVAC cover panel with a hexagonal ventilation pattern beside a 300 mm ruler
Facilities & HVACFDM

A Clean-Sheet Protective Panel for an Exposed HVAC Opening

Debris kept falling into an open HVAC duct. We designed and printed a one-off cover from a clean sheet: impact-resistant, breathable, and stable across temperature swings.

Read case file
Black 3D-printed T-handle tool with a threaded tapered shaft, standing upright
Industrial manufacturingFDM

From Hand Sketch to Hand Tool: Clearing Adhesive Jams on an Extrusion Line

Starting from a basic sketch and a few conversations, we designed and prototyped a purpose-built T-handle tool that clears adhesive jams from a production extrusion machine.

Read case file
Gray resin 3D print of an Assyrian lamassu statue beside a 200 mm ruler
Hospitality & artSLA resin

Scaling an Assyrian Guardian for a Restaurant Signature Piece

A new restaurant wanted a 9th-century-BC Assyrian Lamassu as its signature theme piece. We sourced a 3D model, scaled it, and resin-printed a crisp reference for their sculptors.

Read case file
Have a part like this?

Your project could be the next case file.

Share the component, concept, or production challenge in front of you. We’ll help define the next practical engineering move.

Tell us what you needCall 313.802.0489