Reverse Engineering

What is Reverse Engineering?

Reverse Engineering is a term for the exact reproduction of a master model following the detailed examination of its construction. It is practiced in various industries and traditionally used to analyze another company’s product for benchmarking. 

In the manufacturing industry, the process starts with generating CAD data of an object using digitalization systems. The collected data can be used to digitally display the object’s surface to fully understand the item, and potentially enhance its effectiveness.

How to do Reverse Engineering?

The process of Reverse Engineering starts with generating CAD data of an object with stationary scanning devices. Our professional scanning systems are collecting polygon data by taking multiple scans for the creation of cross-sections with reverse engineering software. The resulting Point Cloud (STL Data) will be used for Feature Extraction, Segmentation and Surface Fitting, before creating a CAD Model. After applying the CAD Tool, the manufacturing process can finalize the first sketches by creating solid samples or surfaces. The model data can be exported into CAD/CAE/CAM systems by using standard formats such as IGES, VDA, STL and STEP.

Parametric Modeling enhances Reverse Engineering

Parametric Modeling is based on a real project with its CAD-data. It displays the model’s different features and uses surface modeling design tools to differentiate the object’s attributes. Parametric Modeling allows the 3D designer to define entire classes of shapes, rather than specific instances. Therefore, parametric models simplify the shape-modification as a whole. With this practice, product design engineering is being revolutionized.

Editing 3D Scans in Reverse Engineering

The digital edit of an object’s CAD data can be done either draft-based, or by using quick-surface modeling tools. Changings in the draft’s data are reflecting the scan’s design and consequently result in an object with different shape.

Quick Surface Modeling is based on high-tech 3D modeling software. The editing is simply done on the scan’s data and then the program automatically creates a surface on the polygon data.

Our experienced engineers are familiar with the most common methods. Let us know about your specifications, and we will recommend the most appropriate method according to your part’s geometry, precision, cost, and application. 

Areas of Application

  1. Modelling of parts without CAD Data (sometimes parts are imported without the CAD data (or the data is lost) and are needed to be reproduced)
  2. Modelling of master models for molding practices (For the creation of molds for different techniques, the required master model needs to be produced)
  3. Need to create data for the recreation of deformed parts or molds (broken parts without CAD data are needed to be reproduced)
  4. Any handmade product (such as clay, wood, styrofoam, etc.) that needs to be transformed into industrial design, can produce CAD Data through reverse engineering
  5.  Since Reverse Engineering, the creation of replications of objects that have a cultural legacy
  6. Industrial modeling parts (clay modelling, model production, etc.)
  7. Revised parts after the mass production (Optimization of the first production line)
  8. Special manufacturing or editing for individual clients
  9. Quality control through sampling after mass production
  10. Control of trim lines in steel parts (important part of quality control)
  11. Control of finishing allowance in cast iron parts
  12. Examination of competing products

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Advantages of Reverse Engineering

  • Reverse Engineering and reproducing can be cheaper than re-importing
  • Understanding existing design and manufacturing techniques
  • Improving competitor’s product without starting from scratch
  • Track down any existing product’s vulnerabilities

Critical Factors while processing Reverse Engineering

  • A professional 3D scanner is a must have
  • Experienced engineer using the scanner due to high complexity
  • The operating engineer needs to have good listening and communication skills in order to fully understand the customer’s needs
  • Detailed specifications (material, size, technical properties, etc.)
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