What can 3D scanning do for reverse engineering?

Reverse engineering involves examining physical objects to uncover their working mechanisms and translating that information into digital models. This approach plays a key role in designing enhanced versions of existing products or rejuvenating outdated ones. For engineers and designers, reverse engineering proves indispensable, especially when dealing with legacy products lacking proper technical documentation or CAD models.

Over time, the methods used for reverse engineering have significantly advanced. While manual measurements were once the norm, modern practices now heavily rely on sophisticated 3D scanning technology. This innovation has opened up a host of new possibilities, streamlining the process and offering precise results to fuel creativity and functional improvements.

3D scanning in reverse engineering

High-tech 3D scanning for reverse engineering is a technology that captures 3D data of objects using lasers or structured lights, from which information about their shapes and sizes can be obtained.
From 3D scanning users can obtain Cartesian points that represent the surfaces of objects and can be converted into models.

Categories of measurement methods

There are different types of measurements for reverse engineering applications, depending on the available sizes, complexity, accuracy requirements and material properties of the object to be scanned. Some common categories are:

Probe the contact: Engineers use probes to measure the surface of the object and obtain its coordinates. Contact scanners are accurate but slow and can damage delicate or soft objects.

Non-contact 3D laser scanner: Portable non-contact 3D laser scanners for reverse engineering mainly fall into two categories: 3D laser scanners and structured light 3D scanners. By emitting laser beams at objects, professional 3D laser scanners can obtain point coordinates of surfaces and objects.

Non-contact structured light 3D scanner: Portable 3D scanners project patterns onto objects and use cameras to record how they deform on their surfaces.
Therefore, these 3D scanners can get the geometric details and even the colors and textures of the products. Non-contact 3D scanners are versatile, accurate and fast for acquiring 3D data.
They can perform full-field 3D scans without causing damage to objects. Some of these 3D scanners may have difficulty with reflective, dark, or transparent surfaces.

Photogrammetry: This technique uses multiple images taken from different angles to reconstruct the shape of an object. Photogrammetry is easy to use, but requires high-quality images and may not capture the finest details.

Scantech’s industrial 3D scanners for reverse engineering

The KSCAN-Magic series 3D laser scanner is the first to combine infrared and blue lasers in one instrument.

It offers five standard working modes:

♦ Large surface scanning (infrared laser with global initiative)
♦ Quick scan (blue laser crosses)
♦ Fine scanning (parallel blue laser)
♦ Depth scanning (single blue laser)
♦ Integrated photogrammetry system.

With two sets of hih-definition industrial cameras, it can meticulously perform 3D scanning. It is suitable for reverse engineering in industries such as manufacturing, energy, automotive and rail.

Workflows from 3D scanning to CAD modeling

Once an object has been scanned using a 3D scanner, it can be reverse engineered using software tools that allow you to modify, modify, analyze, or recreate its design.

Some common steps in reverse engineering using 3D scanning are:

3D scanning: 3D scanning of the part with professional and high-precision 3D laser scanners to acquire Cartesian points.
Point cloud processing: Clean noise, outliers, or unwanted points from the Cartesian point set.
Network generation and optimization: Transform Cartesian points into a mesh model and refine the model so that data can be handled more easily in CAD.
Surface extraction: Import the model into CAD software and extract important surfaces. This step involves generating smooth surfaces that fit the detected parts of the mesh model. Designers can create sketch plans quickly and accurately using the scan model as reference.
Solid modeling and redesign: Converting the surface into a solid model by defining features, parameters, and more. The solid model can be used and modified for further projects.

The advantages of using 3D scanners

Measure complex parts

3D scanning can be used to capture complex shapes that are impossible or difficult to measure with traditional methods.
Thanks to laser scanning and non-contact measurement, it is much easier for portable 3D scanners to measure tight spaces, hard-to-reach areas or parts with complex details such as gears and turbines.
As a result, designers are able to create realistic models that reflect real-world characteristics, and engineers can efficiently design new products based on existing parts.

Enhance creativity and innovation

Using 3D scanning for reverse engineering can enhance creativity and innovation. Using a 3D scanner, designers can explore different ideas and possibilities based on existing objects. For example, a 3D scanner can scan an existing car model and then modify its curves to digitally improve aerodynamics.
Alternatively, a 3D scanner can scan multiple objects and combine them into a new design. This can allow designers to create unique products that meet specific needs.

Save time and money

Using 3D scanning for reverse engineering can save time and money compared to traditional methods.
For example, instead of manually measuring an object with calipers or coordinate measuring machines (CMMs), which can be slow and problematic, a 3D scanner can capture millions of points on an object’s surface in seconds with high precision. This can reduce errors and rework, as well as speed up the design process.