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REVERSE ENGINEERING

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Redesign of components

​Complex geometries and surfaces of all kinds of physical components are redesigned

Possible applications

No CAD data available for physical components?

No problem – through CAD-assisted surface reverse engineering of the digitized mesh lines (3D scan in STL format), we can redesign production-ready CAD datasets!

Additionally, there are several other use cases in product development where reverse engineering provides efficient solutions:

  • Redesign of a component based on existing geometries (e.g., design development for add-on parts for vehicles, machinery, and more)

  • Optimization or further development of an existing product

  • Reproduction of components for which no technical documentation or manufacturing data is available

Mögliche Verfahren

​Whether it is a pure surface model or a parametric solid model depends on the application

vela engineering_reverse engineering_re engineering_funktionsbauteil_scan_.jpg

3D SCAN

​Polygon mesh / facet model (STL)

​3D surface scan of the original component.

vela engineering_reverse engineering_re engineering_funktionsbauteil_cad_.jpg

CAD MODEL

​Parametric surface model

​Native, redesigned surface model in CAD. Perfect quality surfaces with wall thickness.

vela engineering_reverse engineering_re engineering_funktionsbauteil_scan cad_.jpg

COMPARISON

​Functional component

​Minimal deviations between 3D scan and redesigned surface.

GENERAL

With CAD design – the parametric surface redesign – our engineers redesign the component.
The 3D scan (STL) is only used as a reference.
The resulting volume model (STEP) can be edited in any CAD software. Alternatively, we also offer a parametric model with history in the CAD program of your choice.

APPLICATION CASE

  • Parametric Model

  • Volume Model | Solid | Part

  • FEA Simulation

  • 3D Printing

  • CNC Milling

 

PROCESS

  1. The 3D scan serves as a reference/template for the newly constructed model.

  2. The CAD model is built using basic geometric shapes (points, lines, circles) ("Solid Modeling").

  3. Component features, such as separation lines, draft angles, and fillets, are stored in the construction tree.

  4. Measurement values from the scan (e.g., irregular hole dimensions, flat surfaces, etc.) are interpreted appropriately.

RESULT

Parametric, associative CAD model with mathematically correct, high-quality surfaces.

ADVANTAGES

  • Editable CAD volume model, including design history ("design tree")

  • Component can be optimized/modified/evolved

  • CAD data, combined with 2D drawing derivation, is optimal for component manufacturing

 

DISADVANTAGES

  • Deviation from the 3D scan due to redesign may, depending on the application, be larger than with AutoSurface (approximately 0.1 – 0.25 mm); no functional impairment

  • Redesign, especially for freeform surfaces, can sometimes be very time-consuming.

Verfahren 1: Parametrisches Modell durch CAD-REKONSTRUKTION

vela engineering_reverse engineering_re engineering_funktionsbauteil_scan_.jpg

3D SCAN

​Polygon mesh / facet model (STL)

​3D surface scan of the original component.

vela engineering_reverse engineering_re engineering_funktionsbauteil_autosurface_.jpg

AUTO SURFACE

​NURBs surface model (STEP)

​Non-native CAD model through automatic reverse engineering. Moderate quality surfaces. No wall thickness.

vela engineering_reverse engineering_re engineering_funktionsbauteil_autosurface_scan.jpg

COMPARISON

Functional component

Noticeable deviations and inaccuracies between 3D scan and Auto Surface.

GENERAL

This surface redesign involves an automatic molding of the underlying 3D scan (STL). An algorithm calculates the NURBs surface model (STEP).

APPLICATION CASE

  • Surface model, 3D printing feasible, CNC milling

 

 

PROCESS

  1. The 3D scan (STL) is loaded into the reverse-engineering software.

  2. The number of NURBs surfaces is determined, from which the resulting surface model (STEP) will be designed.

  3. The reverse-engineering software creates a direct molding.

  4. Holes in the mesh are manually closed.

RESULT

Non-native CAD model with accurate but moderately quality surfaces. The deviations from the 3D scan (STL) range from 0.01mm to 0.05mm. This surface model is only suitable for organic shapes without edges and holes.

ADVANTAGES

  • Very small deviation from the 3D scan (+/- 0.01 – 0.10 mm)

  • Fast, cost-effective automation for organic shapes without edges and holes

 

 

DISADVANTAGES

  • Very fine-mesh, large STEP files that may cause issues in further use

  • Many surface defects/holes that may need to be manually filled

  • Therefore, CAD redesign is often faster and always cleaner

  • No native data available

  • Errors in the 3D scan are carried over by AutoSurface

​Procedure 2: AUTOMATIC SURFACE REDESIGN

vela engineering_reverse engineering_re engineering_funktionsbauteil_scan_.jpg

3D SCAN

​Polygon mesh / facet model (STL)

​3D surface scan of the original component.

vela engineering_reverse engineering_re engineering_funktionsbauteil_cad_.jpg

CAD MODEL

​Parametric surface model

​Native, redesigned surface model in CAD. Perfect quality surfaces with wall thickness.

vela engineering_reverse engineering_re engineering_funktionsbauteil_original.jpg

​PRODUCED COMPONENT

Functional component

​Smooth production due to the parametric CAD data set and thus guarantees perfect component function!

​Do you have any further questions about 3D digitization or reverse engineering? Feel free to write to us at any time:

We recommend – especially for functional components – the CAD redesign option.

Reason: Only with this option can smooth manufacturing and flawless component functionality be ensured.

​CONCLUSION

CAD redesign vs. automatic surface redesign

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