Reverse Engineering
From the finished component to the design data – this is the principle of reverse engineering. This approach therefore reverses the classic design process by creating a digital data model from the existing product.
Table of contents
What is reverse engineering?
Reverse engineering refers to the process in which a CAD model is prepared from an existing component to reconstruct its design, geometry and function. In the context of STL data (a widely used file format) "reverse engineering" refers to converting the STL data into a 3D model. Output formats include IGES, STEP or SAT.
Quality Analysis creates your 3D model
Reverse engineering is the term used to describe the process by which the surfaces of an existing object are digitised and converted into a CAD model. This process is particularly important in industrial manufacturing and 3D printing, because it is often necessary to reconstruct existing objects if no digital models or design drawings are available. By means of industrial computed tomography or optical measuring equipment (camera systems), we acquire the geometry of your component for you with the highest accuracy.
How does reverse engineering work?
Reverse engineering is the process of analysing an existing physical object or system to reconstruct its structure, function and design. This process is often used if no original CAD data or design drawings are available.
The steps of reverse engineering at a glance
1
Scanning the component:
First, the component to be reconstructed is acquired using a 3D scanner or computer tomograph. This scanning creates a point cloud or mesh that represents the surface of the object.
2
Importing into software:
The scanned data are imported into the engineering software. Here the data are processed and converted into a CAD-compatible model.
3
Reverse engineering and model generation:
The software reconstructs the scanned data into precise CAD surfaces or geometric shapes. In this way a model is prepared that can be used for manufacturing or design.
4
Exporting the CAD models:
The model prepared can then be exported to the IGES, STEP or SAT file format, which makes it possible to use the model in various CAD systems.
For what is reverse engineering used?
Reverse engineering is used to prepare precise 3D CAD models of existing components from scanned data. It permits the reconstruction of components without existing CAD data, the modification of designs and the optimisation of manufacturing processes. The software is therefore primarily used for the digital reconstruction and optimisation of objects in product development, manufacturing, repair and specialised sectors.
Applications of reverse engineering
Prototype development and product design
Rapid preparation and modification of 3D models for new products.
Spare parts manufacturing and repair
Reproduction of components without original CAD data.
Art and cultural heritage
Reconstruction and preservation of historical objects.
Production and machinery manufacture
Optimisation and manufacture of machine components and tools.
Additive manufacturing
Reproduction, optimization and individualization of existing components in printable CAD models.
Automotive sector
Analysis of existing vehicle components for development, optimization and repair.
Aerospace industry
Analysis, reproduction, modernization and troubleshooting of critical components, often for spare parts procurement or performance optimization.
3D measurement methods used
3D measurement methods play a crucial role in analysing and reconstructing components. These methods make it possible to gain detailed insights into the complex structure of objects – their surfaces as well as their internal features – and to depict them digitally. Quality Analysis utilises two advanced methods for the structural acquisition of components:
On the one hand, we use industrial computed tomography, which is able to acquire both the external and internal structure of a component with the highest precision, quickly and non-destructively.
Another method used for digital reconstruction is optical metrology. It is particularly suitable for accurately measuring large and complex components made from a very wide variety of materials. Thanks to mobile optical metrology, we can even work directly on site in your facility. This capability enables us to digitise your parts on site, undertake reverse engineering and respond specifically to your individual requirements and wishes.
Different methods of reverse engineering
In reverse engineering, a distinction is made between two methods: simple reverse engineering and constructive reverse engineering. The two methods differ primarily in the complexity and precision of the models generated:
Simple reverse engineering
During simple reverse engineering, an irregular mesh, usually consisting of triangles, is generated from the scanned data; this mesh depicts the geometry of the object. In simple terms, this method can be likened to stretching a skin over the surface of the object. This method is particularly suitable for the fast and cost-effective reconstruction of simple or less complex surfaces. The models produced are generally less precise and do not provide any editable geometric surfaces.
Constructive reverse engineering
Constructive reverse engineering permits the transformation of existing components into highly precise digital models based on parametric geometry. A crucial advantage of this method lies in the flexibility of the parametric models: changes to the model can be implemented quickly by specifying parameters and relationships. In this way, different variants can be tried or modifications made efficiently.
Thanks to this flexibility, constructive reverse engineering is particularly useful for design optimisation, adaptation to specific requirements and integration into the production process. It provides a valuable basis for further design or analytical processes, because the models generated are both precise and customisable, making the entire development cycle much easier.
In summary: reverse engineering
Reverse engineering is the process of analysing existing physical objects or components and converting them into digital models. This process is often used if no original CAD data are available. The process involves acquiring the geometry of an object by 3D scanning or precise measurement, followed by the conversion of the data into an editable, parametric CAD model. Reverse engineering is used in areas such as product development, spare parts manufacturing, quality control, design optimisation and repair, to reconstruct, improve or reproduce objects. It permits the efficient reconstruction and modification of existing designs and provides a valuable basis for further manufacturing or analytical processes.
