Reverse Engineering Case Study

Problem

Engineering teams often need usable CAD and drawing packages for parts that are worn, discontinued, undocumented, or only available as physical components.

Current State

• Physical parts existed, but digital engineering assets were incomplete or missing.
• Geometry had to be captured from real-world parts with enough detail for reconstruction.
• Customers needed a clearer bridge from scan data to engineering-ready outputs.

Observed Issues

• Incomplete part data and missing engineering drawings
• Legacy geometry without current CAD models
• Risk of inaccuracy between raw mesh output and final CAD reconstruction
• Need to support wear analysis, quality checks, and customer review

Engineering Methods

• Requirements analysis with customer and application context
• 3D scanning and mesh capture
• Mesh cleanup and feature extraction
• CAD reconstruction in Geomagic Design X
• 2D drawing generation in SolidWorks and Fusion 360
• Technical validation against intended use

Proposed Solution

• Built a structured mesh-to-CAD workflow from scan capture through validated engineering models
• Created accurate CAD geometry and 2D drawings for review, manufacturing documentation, and technical discussion
• Adapted the workflow across different use cases including discontinued auto parts, wear analysis, and quality control

Expected Impact

• Accelerated CAD reconstruction from physical parts
• Improved technical clarity for customer decisions and engineering review
• Created cleaner documentation for manufacturing and inspection use
• Demonstrated practical value of 3D scanning in engineering workflows