Reverse engineering turns a physical part into a production-ready 3D CAD file. We do this via 3D scanning (for complex geometry), calipers and digital modelling (for simpler shapes), or a combination. Turnaround 0.5-2 working days. Useful when the original CAD is lost, the manufacturer no longer delivers, or you have no file from third parties.
From physical part to CAD
Physical part + 2D drawing with dimensions – We model directly in CAD (SolidWorks or Fusion 360) from your measurements. Fastest and cheapest for simple parts.
Physical part without drawing, simple geometry – Our engineers measure with calipers and model.
Complex organic part – 3D scan via a specialised bureau or on-site. The scan yields an STL mesh we rework into parametric CAD (wear-deformed features are corrected).
Part + serial number – Sometimes we can consult online CAD libraries or manufacturer documents.
Where the complexity sits
Reverse engineering is more than “measure and draw”.
Wear effects. The original is worn. Your print must match the as-new state, not the worn state. Requires interpretation.
Assembly requirements. Your print must fit into the surrounding assembly. Requires knowledge of standard fits.
Material choice. The original is often a different material than we print. We advise which SLS material best mimics the original behaviour.
For gears or other precision parts: extra attention to module, pressure angle and tolerance is essential.
When reverse engineering pays off
One-off replacements. Almost always if the original supplier will not deliver a file.
Recurring replacements. The CAD is a one-time investment you reuse on every next order.
Parts you want to update (e.g. old metal part replaced by lighter SLS alternative). Reverse engineering + redesign is a nice combination.
Parts with design patents or trademark protection. Check IP rights before reproducing. Our engineers gladly advise on the legal side per case.