Reverse engineering - road to CAD

Reverse engineering is a process that allows you to transform an existing physical object into a computer model, known as a CAD (Computer-Aided Design) model. It is an extremely useful tool in the field of engineering, allowing you to accurately reconstruct the geometry and function of objects in a virtual environment. In the following article, we will present the steps of reverse engineering, define the concept of reverse engineering itself, and discuss its advantages and applications.

Reverse engineering - what is it?

Reverse engineering (reverse engineering) is a process that aims to restore a digital real object. This is particularly important in situations where we do not have technical documentation of a given object, and we want to replicate it, introduce modifications or understand its operation. In practice, it looks like when you need a CAD model or technical documentation of a specific part, component or the entire structure, the first 3D scan of the entire geometry of the required elements is performed, and then based on the obtained data a parametric model is created, which can be further Used for design, optimization or replacement.

Reverse engineering - step by step:

Step 1. Scanning the object: The process begins with scanning the actual object. Advanced 3D scanners are used to obtain precise data on the shape and structure of the object.

Step 2. Creating a point cloud: The scan data is processed into a point cloud, which contains information about the three-dimensional location of points on the object's surface.

Step 3. Processing the point cloud: Specialized software processes the point cloud, eliminating unnecessary artifacts and creating a dense, accurate representation of the object's surface. The resulting model is a mesh model consisting of thousands of small triangles.

Step 4. Creating CAD surfaces: CAD surfaces are created from the mesh model, representing the shape of the object. This is the stage where the model begins to take shape.

Step 5. Optimization and Modifications: In this step, engineers can adjust the model, remove imprecise details, smooth surfaces, and even make modifications according to the individual needs of the project.

Step 6. Generate Technical Documentation: Finally, engineers generate technical documentation of the CAD model that can be used for production, analysis, or further modifications.

Advantages of Reverse Engineering

→  Restoration without documentation

Allows you to recreate an object without access to the original technical documentation.

 →  Modifications and Improvements

Allows you to make modifications and improvements to existing objects.

 →  Accuracy and Precision

Gives you the ability to obtain very accurate models, which is crucial in advanced fields such as aviation or medicine.

Reverse engineering is becoming a key industry supporting the design, optimization, and repair of real parts in many industries and beyond. The ability to digitally reproduce entire, even very complex geometry using precise 3D scanners has allowed the dynamic development of Reverse Engineering, which supports redesign and the creation of new, optimized CAD models based on existing parts.

Currently, reverse engineering is used, among others, in industries such as:

ü  Automotive: Car parts, body parts, rims, bodies, car interior parts

ü  Marine industry: Boat hulls, yacht cabins, motorboats and jet skis.

ü  Heavy industry: Castings, molds, dies, moldings, stampings, stamping dies.

ü  Medition: Implants, prostheses and orthoses.

ü Energy: Turbines, hubs, shafts, rotors and blades.

ü  Architecture and Archaeology: Copying and repairing: monuments, antiques, sculptures, works of art and archaeological sites.

Reverse Engineering Software

Geomagic Design X is a reverse engineering platform. It supports all major 3D scanners, imports raw data, and works with all file formats. It is a professional tool that allows you to obtain a very precise solid model, edit a triangle mesh created based on a point cloud - e.g. file optimization, closing holes and more.

Fusion 360: in the reverse engineering process, we usually use this software to edit a CAD model in order to adapt it to the client's expectations, e.g. create modifications to the original.

Summary

Reverse engineering in creating CAD models is the foundation of a modern approach to design and production. Through meticulous process steps, engineers are able to recreate real objects in a virtual environment, which is of great importance for various fields, from industry to medicine. However, it should be remembered that this process, starting from 3D scanning through data processing, to modeling details, requires advanced tools and skills.

The development of software dedicated to reverse engineering, such as Geomagic Design X or Fusion 360, allows for even more efficient and precise creation of CAD models. This makes the process more accessible and effective for a wide range of engineering professions.

In the future, we can expect further advances in the automation of reverse engineering processes, which will shorten the time needed to create CAD models while increasing their precision. Reverse engineering remains a key tool for innovative projects and will continue to evolve, supporting the development of technology on many levels.