
REVERSE ENGINEERING
Scroll
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

3D SCAN
Polygon mesh / facet model (STL)
3D surface scan of the original component.

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

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
-
The 3D scan serves as a reference/template for the newly constructed model.
-
The CAD model is built using basic geometric shapes (points, lines, circles) ("Solid Modeling").
-
Component features, such as separation lines, draft angles, and fillets, are stored in the construction tree.
-
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

3D SCAN
Polygon mesh / facet model (STL)
3D surface scan of the original component.

AUTO SURFACE
NURBs surface model (STEP)
Non-native CAD model through automatic reverse engineering. Moderate quality surfaces. No wall thickness.

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
-
The 3D scan (STL) is loaded into the reverse-engineering software.
-
The number of NURBs surfaces is determined, from which the resulting surface model (STEP) will be designed.
-
The reverse-engineering software creates a direct molding.
-
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

3D SCAN
Polygon mesh / facet model (STL)
3D surface scan of the original component.

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

PRODUCED COMPONENT
Functional component
Smooth production due to the parametric CAD data set and thus guarantees perfect component function!
We recommend – especially for functional components – the CAD redesign option.
Reason: Only with this option can smooth manufacturing and flawless component functionality be ensured.