3D Scanning in Reverse Engineering
TitleDigital reconstruction at the highest level
Reverse engineering plays a decisive role when original components are no longer available or need to be optimized. With modern 3D scanners, objects can be captured with maximum accuracy and converted into digital models. This data forms the basis for CAD design, 3D printing or CNC production.
The 3D CAD model serves as the basis for the following tasks:
- Reconstruction of old devices and parts, also with the help of 3D printing technologies.
- Error analysis and, if necessary, redesign.
- Analysis of competitor products to optimize own designs.
- Reproduction of parts that are difficult or expensive to procure.
- Improving the performance of existing parts and systems.
- Basis for the development of new products.
TitlePrecise capture of objects
In order to obtain the best possible information from an existing object, you need a particularly accurate measuring device. This is where professional handheld scanners or terrestrial laser scanners come into play, which have already become firmly established in the reverse engineering workflow for many users.
- Precise data capture: Millimeter-precise capture of object details.
- Geometry conversion: Fast conversion into 3D meshes and CAD models.
- Time saving: Fast reproduction of parts for reduced development time.
Object capture with the handheld 3D scanner
The handheld scanner is the ideal measuring device for small to medium-sized objects. It enables the precise capture of components such as gear wheels as well as larger structures, such as the underbody of a truck. With an accuracy of up to 0.02mm and a scanning speed of up to 3 million points per second, the handheld scanner delivers extremely detailed results.
In addition, the live view on the laptop or scanner display offers direct control of the data already captured, making the scanning process even more efficient.
Object scanning with the terrestrial laser scanner
Terrestrial laser scanners are ideal for reverse engineering when it comes to capturing large and complex structures. They enable high-precision measurement of entire vehicles, machines or industrial plants in a short time and with minimal effort.
The resulting point clouds serve as the basis for creating exact 3D models that can be further processed in CAD software. This allows existing components to be analyzed, optimized or reconstructed – a decisive support in the development, maintenance and reproduction of components.
TitleReverse Engineering workflow with a laser scanner
- 3D scanning: Capture the object with a 3D scanner to generate a point cloud.
- Point cloud processing: Clean up and optimize the point cloud by removing noise and filling in missing areas.
- Mesh generation: Convert the point cloud into a triangular 3D mesh to visualize the object geometry.
- CAD model creation: Import the mesh into software to create a CAD model based on the geometry.
- CAD editing: Optimize the CAD model by smoothing, filling voids and making adjustments to meet design requirements.
- Final review: Compare the CAD model to the original to ensure accuracy and project requirements.
TitleSeamless integration into CAD systems
The integration of scan data into CAD systems is a key step in reverse engineering. After an object has been captured with a 3D scanner, the geometry is initially available as a point cloud or mesh model. To further process this data in CAD systems, it is converted into a parametric 3D model using special software. This process includes smoothing the scan data, recognizing surfaces and creating design features such as holes or radii.
The models can then be exported in standard CAD formats and used for design, simulation or production. This allows existing components to be precisely reproduced, optimized or adapted to new requirements.
Title3D scanning in reverse engineering: faster, more accurate, better
3D scanning offers decisive advantages in reverse engineering compared to conventional measuring methods. It enables complex geometries to be captured quickly, precisely and without contact, even in the case of free-form or heavily worn components. Thanks to the high accuracy of the scan data, existing objects can be digitized in detail and used as a basis for further development or reproduction. The use of 3D scanners also significantly reduces manual effort, as the data obtained can be imported directly into CAD software and processed further. This saves time, minimizes sources of error and makes it easier to adapt or optimize existing components for new production processes.
