Articles

Latest scanning technology puts reverse engineering into the hands of novices

Tanya Weaver

High-resolution, highly detailed, fully traceable scan data is the foundation for reverse engineering (Credit: GOM)
High-resolution, highly detailed, fully traceable scan data is the foundation for reverse engineering (Credit: GOM)

Reverse engineering is a design process in reverse.

Starting with an existing product, engineers work backwards through the design process to arrive at the specification. The resulting technical data can then be used to replicate the product in CAD.

There are many reasons why companies would want to reverse engineer products. An obvious one is the replacement of legacy components that have long since gone out of production and where no blueprints exist. 

Reverse engineering relies on the skills of the engineer interpreting the client’s needs. Measurement is usually carried out using one or a combination of 3D systems, of which there are now many on the market including coordinate measuring machines, industrial computed tomography scanners, laser scanners, 3D structured light scanning, time of flight and photogrammetry. 

Often taking just seconds to scan an object’s surface, the resulting point cloud data is then converted into a STL polygon mesh using specialised software. This mesh file is imported into CAD where it is developed into a parametric model, containing a full feature tree. In CAD, the model can be optimised or redesigned. With the final design file complete, the data can then be sent off for production of the physical part.

Data intensive

Being a very data-intensive process, you can’t forget the processing power required to handle all this data. Tim Rapley, MD of Physical Digital, said: “Our highest-resolution GOM scanner can achieve 16 million points with measurement volumes up to 850mm and takes 1.2 seconds per scan. However, we can achieve volumes up to 2m with mobile scanning. We generate over two terabytes a month of mesh data, CAD models and inspection reports. So, as well as the maturity of the software, there’s also been a maturity in the hardware in terms of CPUs, RAM and IT systems needed to process and store that data.” 

While Physical Digital’s reverse engineering projects vary greatly depending on what customers require, the company prides itself on the accuracy of the 3D measurements of high-precision products, particularly critical for some customers, such as those in the aerospace industry where compliance is crucial. To enable it to do that it has invested in sophisticated measurement technologies, such as the GOM ATOS 3D Structured Light optical metrology systems, including GOM TRITOP Photogrammetry. In the past couple of years it also established a robotised measurement cell, the GOM ATOS ScanBox, located in an environmental chamber controlling temperature and ambient light and logging humidity and barometric pressure, which can carry out automated high-resolution measurement and inspection of components that are up to 2m3

Easy-to-use options

On the other end of the spectrum, recent years have seen the entry-level and mid-range 3D scanner market grow with new vendors offering a range of more affordable and easy-to-use options. And more affordable doesn’t mean less sophisticated, as many of these new handheld scanners provide high accuracy and precision.  

Last December, the International Data Corporation published a report – IDC Innovators: 3D Scanning, 2019 – in which it profiles four companies that are expected to make an impact on the market. All four, Artec3D, Occipital, Scan Dimension and Calibry 3D, have launched professional handheld 3D scanning technologies that are recognised for their ease of use or affordability.   

Together with hardware, software is also becoming more accessible. Companies like ReverseEngineering.com have created plug-ins that integrate scanning hardware directly into CAD software.

There is also QuickSurface, a product developed by KVS that had its first software release, QuickSurface 1.0, at the end of 2019. The aim with KVS’s software is to provide intuitive tools that enable novices to easily turn a mesh-based file from a 3D scanner into surfaces that can be used in most CAD programs.

KVS has signed a partnership agreement with Thor3D, which will see its software sold in a bundle with the Calibry 3D scanner. This is in answer to a strong trend it’s seeing where users unfamiliar with 3D scanning want to get into the industry and need accessible and affordable technology without a steep learning curve. 

Despite this rush for 3D scanning technology, there is still a place for reverse engineering service providers like Physical Digital. “We pride ourselves on high-resolution, highly detailed, fully traceable scan data or measurement data, which is the foundation for reverse engineering. Our team have an understanding of measurement accuracies and uncertainties, which is crucial when going from scan to CAD. We have that chain of custody between the part, the data and the CAD model,” said Rapley.


Want the best engineering stories delivered straight to your inbox? The Professional Engineering newsletter gives you vital updates on the most cutting-edge engineering and exciting new job opportunities. To sign up, click here.

Content published by Professional Engineering does not necessarily represent the views of the Institution of Mechanical Engineers. 

Share:

Read more related articles

Professional Engineering magazine

Professional Engineering app

  • Industry features and content
  • Engineering and Institution news
  • News and features exclusive to app users

Download our Professional Engineering app

Professional Engineering newsletter

A weekly round-up of the most popular and topical stories featured on our website, so you won't miss anything

Subscribe to Professional Engineering newsletter

Opt into your industry sector newsletter

Related articles