Reverse engineering is evolving into a complex, multidimensional field with a spectrum of burgeoning applications. From reconstructing pre-CAD era parts to crafting orthotics and prosthetics and updating CAD models post-production, the scope is expanding continuously.

Advancements in computing have enabled the development of highly sophisticated metrology sensors and robust software. With the rapid pace of technological innovation, there is a high likelihood that there is an application that ideally suits your needs.

Specialization in an Advancing Tech Landscape

The process of reverse engineering a physical part into a digital model starts with collecting data points using metrology sensors. These data points are then transformed into a connected mesh, which is further processed into surfaces or a solid model. The advancements in computing power and software have greatly improved each step of this process, resulting in faster and more accurate data collection, meshing, and CAD conversions.

Advancements have made high-end and low-end uses more accessible to non-experts. For instance, orthotics and prosthetics, requiring lower resolutions, are accessible through simple scanners attached to tablet computers, operated by virtually anyone.

Moving up the ladder, some applications demand tighter tolerances, such as consumer product design, where scanning and original design work intertwine. Precision reaches around 50 μm in this tier.

The demand for maintenance, repair, and overhaul applications is increasing, requiring accuracy within single-digit microns. This level of precision necessitates advanced software usage and intricate equipment handling, particularly for tasks like scanning aircraft landing gear. Achieving high levels of accuracy and resolution down to single-digit microns requires advanced equipment such as high-accuracy LiDAR or white-light scanners. For instance, when scanning an aircraft landing gear for repair, a single-digit micron accuracy is crucial, requiring skilled operators to operate the scanning equipment and use the software at the back end to generate an accurate CAD model.

The pinnacle requires top-tier skills and equipment, especially for recreating and upgrading legacy parts for better performance or manufacturing efficiency.

Vendor Specialization Meets Diverse Needs

Vendors now offer specialized scanners and software for diverse applications, spanning orthotics, building information management, and various technical manufacturing domains. Whether you need a vendor or service bureau, they are available to meet your specific needs.

Capturing Existing Realities

Ronnie Hensley, Exact Metrology's Reverse Engineering Manager, explores the vast capabilities of 3D scanning and highlights the immense improvements in scanner speed and accuracy that have taken place over the last 13 years. Thanks to the use of laser-equipped scanning arms, accuracies of 0.002 inches (50 μm) can now be achieved, which is remarkable progress in precision.

It’s also interesting to note that beyond engineering, artists utilize reverse engineering for archiving their sculptures. For engineering, mock-ups of parts needing assembly fitting are scanned and transformed into 3D models, facilitating iterative modifications until a perfect fit is achieved.

Empowering Industries, Saving Time and Money

Reverse engineering is not limited to recreating parts but involves optimizing operations and conserving significant resources. Several industries, such as hydro power, have reduced their hours by leveraging reverse engineering. For instance, in the case of turbine fin replacements that were earlier repaired through labor-intensive methods, scanning and creating an exact match via milling have streamlined the process, saving thousands of hours.

In the automotive sector, documenting as-manufactured parts has been a game-changer, helping to achieve the desired fit and finish. This process mainly benefits companies transitioning from internal combustion to electric vehicles within their product lines.

Scanner and Software Improvements

Integrating scanning software and sensors is advancing, leading to better data capture and seamless integration. With the help of advanced computing, exposure settings are automated, and processing algorithms are intelligent, leading to improved data accuracy and model fidelity. Specialized software companies like Verisurf have benefited from these advancements, providing comprehensive solutions. In addition to packaging improvements, the software can process scan data into watertight models, creating full-featured solid models that enhance data accuracy and usability.

Reverse Engineering for All

In recent years, the availability of consumer electronics has made reverse engineering accessible to more people. Smartphones with LiDAR sensors and apps that use photogrammetry software can now be used for basic scanning of larger objects or artistic purposes. Although these technologies have limitations, they represent a significant advancement from a decade ago when such processing power was unimaginable. This progress hints at a promising future for reverse engineering.

Anticipating Future Possibilities

Fuelled by faster computing, the future holds promising applications for elastomers, hot parts, and mass customization. AI integration is poised to simplify reverse engineering further, driving continuous technological improvements.

The journey of reverse engineering, propelled by innovation and technological leaps, is opening new frontiers. As Scott Green from 3D Systems predicts, software algorithms powered by AI and machine learning will further revolutionize this realm.