Reverse Engineering: When You Need to Get from Point B to Point A
Unlike the traditional engineering process of designing a part, product or component from the ground up, many times in life we need to start with an existing item and work backwards to solve a problem. It’s a process known as reverse engineering, and it begins by obtaining accurate data about the object.
Industrial Inspection & Analysis (IIA) is proud to have been an early adopter of laser and CT scanning and recreation of geometry for the manufacturing industry — from medical devices and heavy equipment to firearms, tooling and plastic companies.
Reverse engineering is used — by both corporations and individuals — for a variety of reasons. Some common scenarios we see at IIA are highlighted below.
Scenario #1: No Design Files Exist
Reverse engineering is commonly used to accurately reproduce older parts (legacy components), where the original drawing no longer exists or cannot be accessed. Among the most interesting uses of this technology is in the preservation of historical objects.
Such was the case when the owner of a vintage John Deere tractor (circa 1945) broke the shaft during restoration and needed to replace it. IIA was able to scan the broken item and create a 3D model that allowed the collector to have a new part manufactured, true to the original.
IIA was also able to help a car connoisseur reproduce a Corvette-specific wing nut before entering a car show. Another collector — proud owner of a vintage Mazda RX-7 — needed IIA’s help replicating an aluminum intake tube. Data in hand, he then found an overseas supplier who could produce the part in aluminum using 3D printing.
On a much grander scale, voluminous data gathered from top-to-bottom 3D laser scans in 2010 has proven priceless in reconstructing the Notre Dame Cathedral in Paris after a catastrophic fire in 2019. In addition to laser scanning, material analysis was used to determine the origins of marble and wood used in the cathedral so it can be replaced with materials featuring the same grain structure.
Scenario #2: A Current Product Does Not Match Original Design Files
In other cases, a product or piece of equipment has evolved over time to the point where it no longer matches the original CAD design files or blueprint.
This commonly occurs with tooling, such as classic injection molding dies, that has been in use for decades. Over the years, tooling may require repairs — and often, those fixes go undocumented. When the design files do not keep pace with the evolution of a product, no one knows exactly what changes have been made to the original design. This situation often goes unnoticed until it’s time to replace the equipment and potential replacements do not match design specifications.
IIA has a variety of tools available to quickly scan the latest version of the item so a replacement can be made and your design documentation is up to date. When needed, we can supplement our laser scanning with coordinate measuring machine (CMM). In one such case, we used a laser scanner to scan the exterior of a large metal part and then used CMM to profile internal threaded features.
Scenario #3: Foreign Manufacturing & Supply Chain Issues
As some of our customers have discovered, when dealing with foreign manufacturers of parts and equipment, it’s not always easy or possible to obtain accurate or complete design files for their part.
For instance, IIA stepped in to help when an ore mining customer in Northern Minnesota faced supply chain issues for a foreign-made part used in its rock crushing machines. Using our mobile laser scanners and FARO arms, we came to the work site to capture the point data needed. With accurate design files in hand, the customer was able to supplement production domestically for faster turnaround times than their foreign supplier could provide.
Another company that makes carbide teeth inserts for the mining and construction industries began to notice discrepancies between inserts made overseas and the ones manufactured domestically. IIA was able to pinpoint the exact differences between the two and help the customer make design changes to ensure that the next iteration of the part would work with all applications.
Scenario #4: Product Comparison or Enhancement
Reverse engineering and 3D scanning are invaluable when engineers are redesigning or enhancing a product or part, or if a company wants to conduct a competitor analysis.
Manufacturers of large construction equipment such as front-end loaders, backhoes, and excavators often turn to IIA to capture point data on a competitor’s product. This comparative data can help inform their own design to build a better product than currently exists in the marketplace. 3D scanning also allows manufacturers to build products that work seamlessly with another company’s products – such as a new scope for a gun or a case that fits snugly around a cell phone.
Scenario #5: When a Custom Fit is Critical
We are particularly proud to provide reverse engineering data that helps to improve quality of life, such as the many projects we’ve supported in the medical industry.
For example, IIA has digitally reproduced casts and models to help medical manufacturers create custom-fitted dental implants or bone plates used with prosthetic limbs. Rollx trusts IIA to provide the precise interior measurements it needs to create custom handicap accessible vans that meet the unique needs of each customer.
Whether you’re driven by authenticity in car restoration or want to build a better mousetrap, IIA is a great place to start for reverse engineering.
360-Degree Reverse Engineering Capabilities
Along with dimensional analysis of a physical object, IIA offers a wide range of lab testing, including mechanical, chemical, environmental, material, that can take reverse engineering to the next level. Our full-service capabilities allow our customers to faithfully reproduce something that was made in the past -- from exterior coatings to the interior crystalline structure. And once reverse engineering is complete, our team can help you enhance the design.
Scanning at Your Site
Our state-of-the-art scanning services are not limited to our labs. For larger equipment, we can bring our cutting-edge mobile equipment to your site for a faster turnaround and greater convenience.
