Reverse Engineering

Our process consists of a fixed, systematic workflow. We start with calibration and verification of the scanner, followed by 3D scanning of the object (optical or via CT). Then we clean up the scan data and convert the mesh to a CAD model using specialized reverse engineering software such as Geomagic Design X and QuickSurface. Finally, we validate the result with a color plot that visualizes the deviations between the CAD model and the original scan. This way, you always receive a high-quality and validated end result.

Depending on the part, we use our optical 3D scanners based on structured or laser light, optionally combined with photogrammetry, or one of our X-ray CT scanners. CT scanning is particularly suitable for parts with complex internal geometries that are not optically accessible. For larger objects that cannot be moved, we have various mobile scanners, ranging from small handheld to large tracking systems.

You will receive a CAD file in the format of your choice: STEP, IGES, or Parasolid (X_T / X_B). These are universal formats that can be opened in virtually any CAD software. Additionally, you will also receive the original scan data (STL) and a validation report that visualizes the deviations between the CAD model and the scan.

A 3D scan produces an STL file: a mesh of triangles that describes the shape of the object. This is very accurate but not editable in traditional CAD software. In reverse engineering, we convert this mesh into a true CAD model with editable features such as planes, cylinders, NURBS surfaces, and boolean operations. This allows you to modify the design, run simulations, or use it for production.

After creating the CAD model, we compare it with the original scan. A color plot visualizes the deviations between both, so you can see at a glance where any differences are located. Adjustments are still possible at this stage to eliminate discrepancies. We work as much as possible according to general design principles such as perpendicularity and concentricity.

Common applications include restoring missing CAD data from existing parts, redesigning or improving products, preparing parts for production via CNC machining, 3D printing, or injection molding, and digitizing legacy parts for which no original design is available anymore.

Yes. When standard prismatic shapes (planes, cylinders) are not sufficient, we use NURBS surfaces (freeform surfaces) or a combination of both. Think of organic shapes, design parts, or complex mold surfaces. With software like Geomagic Design X and QuickSurface, we bridge the gap between 3D scanning and traditional CAD software.

The accuracy depends on two factors: the accuracy of the underlying scan on one hand, and the manufacturing quality of the part itself on the other. Typical accuracies per material type: machined parts ± 0.05 mm, plastic parts (3D printing, injection molding) ± 0.25 mm, and cast iron parts ± 1–2 mm for the overall shape (post-machined functional zones offer higher precision).

In reverse engineering, we model the part according to the intended geometry. A sink mark or dent on a surface, for example, is modeled away to a perfect flat surface, which deliberately results in a deviation from the scan. These choices are always transparently documented in the validation report, where we visualize the differences between scan and CAD model. With our ISO 17025 accredited measurement equipment, we achieve scan accuracies down to 0.005 mm.

The lead time depends on the geometric complexity and the number of unique features of the part. Simple prismatic parts are faster to model than complex freeform surfaces. But the number of features also plays a role: many different features extend the timeline, even if they are not individually complex. Each project is assessed on a case-by-case basis. Contact us for a concrete estimate, we always respond within 24 hours.

The price depends on the complexity of the part, the type of surfaces (prismatic vs. freeform), the desired accuracy, and the output format. We create a customized quote for each project. Request your quote here, you will receive it within 24 hours.