Dr-Zocchi Dr-Zocchi
Active Research

Where old parts
become new again.

We don't just source parts — we reverse-engineer them. From callipers and scan data to production-ready components: this is how we bring 30-year-old suspension back to life.

📐Reverse Engineering
🖨️3D Printing
🎨CAD & Rendering
🔬Prototyping
Current Projects The Process Custom Work Tools & Stack Open Source

Current Projects

What's on the bench right now.

Active development — from first measurement to production candidate.

Completed

1. Gen MONSTER Top DROP Crown rebuildt!🫵👀

We ran a full production cycle for the older DROP crown on customers demand to make it 1:1 as original and have some minor numbers in stock now.
Based on a detailled 3D model it was possible to create a full CNC program set in MasterCAM and HQ milled it out of a 240x80x100 Aluminium 7075 T6 block.👍
You can shop is here : .....

Phase 7 — completed
In production

Bomber 35mm Seal Kit in Production

Full set of main seals for Marzocchi forks like Shiver DC, 66, 888 and more - a complete set incl. oil seals, dust wipers and SAG ring.
Our 2nd full set of seals made out of XNBR (Z1's 30mm were the first) to match better dynamic requirements and improved UV protection. We also changed the colour to gray to make it brand specific (new picures todo).

Phase 6 — batch release
At manufacturer

2003-2006 Tool 12mm / 120mm R5164/C

Looking so simple, but for some users it is a pain-in-as-tool. Marzocchi contructed some of the forks in a way you need such socket tool with very thin walls - standard one will no fit.
The workaround it to grind a normal down. The professional one is to have the suitable tool and don't mess around.

Phase 5 — release drawings
In production

1997+ Z1 Bomber Stanchions

New stanchions made out of Alu 7075 T6 for Bomber Z1 100mm travel, hard coated type III 45µm.
Current challenge: sourcing correct manufacturing parameters in hardness, Ra/Rz and porosity spec for oil impregnation.
1st batch of 10 master samples have been done and are in analysis.

Phase 6 — batch release
In production Article →

Marzocchi 380 Knob — lower parts often get loose

Red Lower LO-Rebound Knob 549258 (2014-2018) used in Marzocchi 380er forks.
Easy to lose, now we make new ones.

Phase 5 — release drawings

The Process

From worn part to fresh production run.

Every component we produce starts as a dead original. Here's how we turn it into something you can order today.

🔩
STEP 01

Acquire the original

We source NOS (new old stock) or used original Marzocchi parts from riders, shops and estate collections worldwide. The older and rarer, the better. This is the ground truth everything else is built on.

NOS partsdonor forksdisassembly
📏
STEP 02

Measure & document

Each part is measured with digital callipers, plug gauges and go/no-go gauges. Critical dimensions are measured 5–10 times and averaged. We document material hardness, surface finish, lip geometry and spring rates where relevant.

callipersCMMtolerance stacksmaterial analysis
🖥️
STEP 03

Build the CAD model

Measurement data becomes a parametric 3D model in SolidWorks. Every radius, draft angle and interference fit is captured. The model and all its features are a single source of truth for all downstream work — drawings, prints and tooling.

SolidWorksparametric modellingGD&T
🖨️
STEP 04

Print & test the prototype

Before committing to tooling, we print functional prototypes on FDM and resin printers. Seal profiles are tested for fit and lip deflection. Spacers and bushings are tested for dimensional accuracy under load. We iterate fast and agile.

FDMresin SLAfit testingiteration
📄
STEP 05

Release engineering drawings

Once the model is validated, we produce fully dimensioned 2D engineering drawings with tolerances, surface finish callouts and material specifications. These go to the manufacturer — no ambiguity, no phone calls. We exchange 2D drawings in PDF and 3D models in STEP format.

ISO 2768GD&TDXF / PDFfirst article inspection
🏭
STEP 06

Production & first article inspection

The manufacturer uses the STEP model to generate 5-axis CNC code and run machining simulations in MasterCAM — critical for non-standard free-form geometry where programming runs by machines only. The STEP file is also used to drive the quotation process. If needed, the manufacturer then produces a first article batch. Some parts don't need a demo part and will go straight to production to save time and costs. Every dimension on the drawing is verified against the part, compared to the original, and only when all critical dimensions are within spec does a part enter our catalog.

STEP5-axis CNCmachining simulationfree-form geometryFAICMM reportbatch release

Custom Work

Need a part that doesn't exist yet?

We take on unique and very small-quantity productions on demand. You bring the idea — we bring the engineering, the CAD model, the prototype and the production run.

What you need to bring

01

An idea

The minimum we need. Describe the part, its function, what fork it fits and what is failing. We will do the measurement and modelling work from scratch.

Minimum entry point
02

Research data

Even better: bring measurement data, photos of the original, wear patterns and known dimensions. This cuts time and cost significantly and improves accuracy.

Faster & more accurate
03

CAD data (STEP)

The ideal starting point. If you already have a STEP file or SolidWorks model, we can go straight to prototyping and skip reverse-engineering entirely.

Straight to prototyping

What we deliver

STEP fileEngineering drawing (PDF)3D-printed prototypeSmall production batchFirst article report
⚠️

Good to know before you reach out

  • ›Minimum order: 1 piece — yes, really.
  • ›Lead time: 4–12 weeks depending on complexity and tooling requirements.
  • ›Not suitable for safety-critical structural parts (steerer tubes, dropouts, fork crown).
  • ›We focus on seals, bushings, knobs, caps, spacers, o-rings and similar wear or functional parts.

Start a project

Have a part in mind?

Tell us what you need — fork model, part description, and whatever data you have. We'll come back to you with an assessment and a rough timeline.

Tools & Stack

What we work with.

📐

Measurement

  • ›Digital callipers (0.01 mm resolution)
  • ›Plug gauges & bore gauges
  • ›Go/no-go gauge sets (metric)
  • ›Shore A durometer (rubber hardness)
  • ›Digital force gauge (spring rate)
🖥️

CAD & Modelling

  • ›SolidWorks (parametric solid modelling)
  • ›SolidWorks Drawings (2D engineering drawings)
  • ›SolidWorks Visualize (rendering)
  • ›Blender (additional visualisation)
  • ›DXF / STEP / IGES export for manufacturing
🖨️

3D Printing

  • ›FDM — PLA, PETG, TPU, PA12
  • ›Resin SLA — standard & ABS-like
  • ›Slicer: PrusaSlicer, Cura
  • ›Post-processing: sanding, vapour smoothing
  • ›Tolerance testing against originals
📄

Documentation

  • ›Engineering drawings (ISO 2768 tolerances)
  • ›First article inspection reports
  • ›Material certificates (RoHS, REACH)
  • ›Git version control for CAD files
  • ›Public repository for community access

Dr-Zocchi Lab

We make ideas for vintage parts reality.

Marzocchi stopped. We didn't. From a worn knob to a full CAD model, from a broken seal seat to a fresh production run — if the part existed once, we find a way to make it exist again. Got a part in mind? Tell us.