Historic Hagen Baluster Replication Project | Gannon MakerSpace

We’re happy to share an incredible story of how history and modern technology came together in one of Erie’s most beautiful historic homes. The “100-year-old answer” is a phrase often used by Thomas B. Hagen, Founder and Chairman of the Historic Erie Preservation Trust, and his team when restoring homes in Erie’s West Sixth Street Historic District. But sometimes, preserving the past takes a little help from the future.

Recently, the restoration team at Kidder Jefferys Construction, led by President Mike Jefferys, faced a unique challenge at the 1895 Germer • Walker House on 538 W. Sixth Street. Several wooden balusters along the home’s grand staircase were damaged or missing. These weren’t just any balusters—they featured intricate spiral designs that made finding replacements nearly impossible. After searching for craftsmen who could replicate them affordably and on time, Jefferys turned to a modern solution: 3D printing.

At Gannon University’s Institute for Health and Cyber Knowledge (I-HACK), a team of skilled engineers and designers, led by Design and Fabrication Engineer Nick Devine, took on the challenge. Using advanced 3D laser scanning technology, they captured the exact shape of the original baluster, creating a precise digital replica. This scan allowed the team to design an identical model using CAD software and prepare it for 3D printing.

The new balusters were printed in durable material and reinforced with metal rods for safety and stability. Once finished, they were carefully sanded and coated to match the aged look of the original wood. The final step involved installing the printed balusters seamlessly alongside the existing staircase, restoring the grand entryway to its original beauty.

This collaboration between Kidder Jefferys Construction and Gannon University’s MakerSpace shows how old and new techniques can work hand in hand. By combining traditional craftsmanship with cutting-edge digital fabrication, the project not only preserved an important piece of Erie’s architectural history but also demonstrated how technology can make restoration faster, more precise, and more affordable.

The success of the Germer • Walker House project marks just the beginning of many future collaborations between Gannon University MakerSpace and Erie community. Similar restoration efforts are already underway for several other historic homes along West Sixth Street. Through projects like this, Gannon’s MakerSpace continues to show how innovation can help communities protect their past while embracing the tools of the future.