Synology DiskStation NAS devices are widely used by factories, manufacturing companies, and businesses for data storage, backups, and production workflow management. However, when a RAID 1 array encounters an I/O device error, it often indicates read/write errors, bad sectors, or degraded RAID integrity, making stored data inaccessible.
This case study details how we successfully recovered critical business data for a factory printing company in Guildford from a Synology DiskStation RAID 1 array with 4 disks, after I/O errors prevented access to essential files.
As Guildford Data Recovery, Surrey’s oldest and best data recovery company, we have 25 years of experience using RAID reconstruction, deep sector scanning, and advanced NAS data extraction techniques to restore lost business data securely.
Synology DiskStation RAID 1 with I/O Device Error
A Guildford-based factory printing company contacted us after their Synology DiskStation NAS failed, with the following issues:
- The RAID 1 array reported “I/O Device Error” when accessing data.
- Files could not be opened, transferred, or copied.
- The NAS interface showed degraded RAID health, but rebuilding failed.
- The storage contained critical factory design files, client order records, and production schedules.
Since I/O errors can lead to complete RAID failure if ignored, an immediate professional recovery solution was required.
Diagnosis & Evaluation
When the Synology DiskStation RAID 1 NAS (4 disks) arrived at our secure cleanroom facility, we conducted a full RAID and drive diagnostic. Our findings:
- Multiple bad sectors on two drives, causing I/O read/write errors.
- RAID metadata inconsistencies, preventing proper disk mirroring.
- No full mechanical failure yet, meaning immediate imaging and RAID reconstruction were possible.
Since continuing to use a RAID 1 array with I/O errors can worsen data corruption, we prioritized RAID reconstruction and direct data extraction techniques.
The Recovery Process
1. Cloning & Imaging All RAID 1 Drives to Prevent Further Data Loss
To preserve all recoverable data, we:
- Created forensic sector-by-sector clones of all 4 RAID 1 disks.
- Used deep scanning tools to extract readable sectors while bypassing bad areas.
2. Rebuilding the RAID 1 Array & Repairing File System
Since RAID metadata was partially corrupt, we:
- Reconstructed the RAID 1 array outside of the Synology NAS system.
- Repaired file system inconsistencies to restore lost file structures.
3. Extracting & Verifying Business-Critical Data
Once the RAID array was successfully rebuilt, we:
- Recovered all printing company design files, client orders, and production records.
- Restored job scheduling data, invoices, and archived customer projects.
- Transferred the fully restored data to a secure external backup device.
The Results: 100% Data Recovery Success
Thanks to our RAID 1 reconstruction and deep forensic sector recovery techniques, we successfully recovered 100% of the factory printing company’s lost business data, including:
✅ Design files and print job configurations
✅ Client orders, invoices, and production workflow records
✅ Organized file structures restored for seamless operations
The factory was able to continue printing operations without data loss, preventing financial setbacks and workflow disruptions.
Why Choose Us?
With 25 years of experience and tens of thousands of successful RAID recoveries, we are England’s leading Synology NAS data recovery specialists. Our expertise includes:
✔ RAID 1 reconstruction & RAID metadata repair
✔ RAID degradation recovery & NAS firmware troubleshooting
✔ Business document, design file, and operational data retrieval
✔ Secure & GDPR-compliant data recovery services
If your Synology NAS is showing I/O device errors, failing to mount, or preventing access to critical business files, stop using it immediately and contact us for expert RAID data recovery.