Reverse engineering is a process that involves making a design model from a physical product. At MicronPA, our 3D modeling services make it possible to reverse engineer parts that have an incomplete computer-aided design (CAD) model or lack one entirely. Learn about the process and how you can benefit from our reverse engineering services.

What Is the Reverse Engineering Process?

The reverse engineering process aims to understand the functions of the assembly or component. Reverse engineering duplicates the physical product into CAD software to identify how each part interacts to make the overall system or assembly work.

Nearly any object of any size and complexity can be reverse-engineered. Our team will use a scanning laser to create a 3D scan of your object. Once we capture the data, we will create an STL mesh to load into a 3D printer or create CAD models from as-built data. We can also make tetrahedral meshes for finite element analysis (FEA) simulation.

Our reverse engineering service follows these steps:

  1. Obtain industry knowledge: Since your team consists of industry experts, our engineers will work with you to gather essential information about the product’s purpose and design intent. This information can include the physical product (intact or damaged), prototype, older model, blueprints, manuals and written data. Including your expertise in the reverse engineering process allows us to produce the best results.
  2. Digitize the product: Our team will use the information gathered as starting points to create a digital model of the product. We create these digital models by performing a computed tomography (CT) scan. The CT scan creates a 3D model of the product and provides data such as width, height and volume. These part pictures are computerized and accurate.
  3. Convert the digital model file: Once our team has obtained an accurate CT scan of the product, we can convert the images into a CAD model. Your team can use the CAD model for your future design projects.

The Benefits of Reverse Engineering

Reverse engineering is beneficial for many reasons, as it allows you to:

  • Complete design data: When you have gaps in your CAD model, you can’t move forward with the manufacturing process. Reverse engineering helps you fill in those holes and make edits as needed to prepare for mass production.
  • Refresh outdated designs: If you haven’t created or updated a component in several years, you may not have a viable CAD file available. Using reverse engineering can give you a foundation for altering the part and upgrading it to adhere to modern performance standards.
  • Find vulnerabilities: Reverse engineering breaks a component down to its various functions, allowing you to find any vulnerabilities in your current design. While the CT scan alone may reveal some weak points, the CAD model will give you quantitative measures you can change.
  • Create reference models: Creating a CAD file with reverse engineering provides you with a digital model you can reference throughout the manufacturing process. Whether you rely on your new CAD model to make alterations or use it as your primary design for mass production, it will quickly prove useful.
  • Document prototypes: If you created an experimental prototype by hand, you don’t have a CAD file to reference for mass manufacturing. Reverse engineering helps you work backward from your prototype and create a blueprint for future parts.

Reverse Engineering Applications

Reverse engineering is versatile, with a broad range of uses, including:

  • Digital archiving
  • Machining and molding
  • Outsource manufacturing
  • Part-to-part comparison
  • Model creation for legacy parts
  • 3D printing
  • 3D animations and visualizations
  • Design mating parts or packaging
  • Patent drawings

When your CAD drawing is complete, you can use it to:

  • Preserve and document item design.
  • Blueprint parts for government inspection.
  • Replace obsolete or legacy parts or items.
  • Create models and drawings from a handmade prototype.
  • Benchmark an item.
  • Improve the design, cost and function to make an item.
  • Create a mold for a part.

FAQs About Reverse Engineering Services

Our most frequently asked questions about reverse engineering include:

What Is the Purpose of Reverse Engineering?

Reverse engineering is necessary for an in-depth understanding of systems and products. Designers use reverse engineering to analyze tolerances, design intent and key functions.

How Is 3D Scanning Used in Reverse Engineering?

3D scanners create a digital replication of the product being reverse-engineered. The 3D model can be modified and analyzed to specific design specifications.

How Is CAD Used in Reverse Engineering?

With CAD, engineers can use a 3D scanner to create a digital model of the product. The product scan can be deconstructed virtually to understand its design and purpose. We can deliver your CAD model in any necessary file format, including initial graphics exchange specification (IGES), Standard for the Exchange of Product Data (STEP) and stereolithography (STL). Available data outputs include:

  • Hybrid CAD model for surfaces and solids (IGES and STEP)
  • 3D surface model (IGES and STEP)
  • Polygonal model (STL)
  • Feature-based solid model and assemblies (IGES and STEP)
  • Abaqus
  • PATRAN pre- and post-processing software for FEA

Why Work With MicronPA for Reverse Engineering?

MicronPA offers expert reverse engineering services in York, Pennsylvania and throughout central Pennsylvania. We leverage our extensive experience, deep engineering knowledge and dedicated professionals to complete reverse engineering projects of any difficulty. We can transform damaged physical products or incomplete product data into a functional CAD model.

MicronPA reverse engineering services are beneficial for these applications:

  • Parts without an accompanying CAD file
  • Custom Manufacturing
  • Architectural engineering
  • Civic engineering
  • Facility maintenance
  • Product design improvement initiatives

Contact Us for 3D Modeling and Reverse Engineering Services in Central Pennsylvania and Beyond

MicronPA offers custom solutions for your design and inspection needs. With 3D modeling services and other inspection types, we can find the right solution to help you improve your manufacturing operation’s accuracy and efficiency. From our base in York, we serve companies in Pennsylvania and beyond. Get a free quote today, or contact our team to learn about our capabilities.