The purpose of reverse engineering is to test and improve its products, to evaluate competing products and their technical characteristics, to simulate their performance dynamics with other structural units or in the environment, to assess violations of potential copyrights, etc. Therefore, reverse engineering is an indispensable tool for improving existing products and developing new products.

Reverse engineering is an essential department of the geometrical layout and manufacture application area, and this method has been extensively diagnosed as being an essential step within side the product improvement cycle. The use of reverse engineering will in large part lower the production time and costs. Reverse engineering is the procedure of manufacturing layout information within side the shape of CAD version from the bodily component within side the procedure of the product layout. In evaluation to the conventional manufacturing sequence, opposite engineering generally begins with measuring a current object, so that a strong version may be deduced on the way to employ the benefits of CAD/CAM/CAE technologies.

Reverse engineering technique incorporates three foremost steps which are used to extract expertise approximately the design, material, structure, floor qualities, and working situations of the product etc. The procedural steps are described as the scanning phase, factor processing phase and solid modelling. Before reverse engineering, some factors have to be taken into consideration in making plans, including motives for which an element is to be reverse engineered, element size, element complexity, element material, element geometry, element finish, etc.

Ability to reduce inspection times or turnaround times, reverse engineering approaches are gaining popularity in today’s competitive market as today’s global environment is rapidly changing and seeking new ways to overcome the time constraints and find new products and improve them. But future work is also needed in this area as there is potential for improving reverse engineering approaches as they lack efficiency and accuracy. Most reverse engineering algorithms require additional improvements for better results and less chance of errors.

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Reverse engineering is also called back engineering because it involves working backward through the original design process.

The challenge is to gain a working knowledge of the original design by disassembling the product piece-by-piece or layer-by-layer because of limited knowledge about the engineering methods that went into creating the product.

In some cases, the only way to obtain the design of an original product is through reverse engineering. The original 2D drawings are no longer available for some older products that have not been manufactured for 20 years or more.

As some companies may no longer be in business, there will be no way to contact the original manufacturer, and reverse engineering comes to the rescue.

An organization will acquire an example of the product and take it apart to examine its internal mechanisms for reverse engineering. This way, engineers can unveil information about the original design and construction of the product.

When reverse engineering a mechanical product, engineers will start by analyzing;

• the dimensions and attributes of the product,
• whether it is an aircraft, ship, vehicle, computer, or
• piece of industrial machinery.

Engineers make measurements of the widths, lengths, and heights of key components in the product during this analysis because these dimensions will also reveal the product’s performance.

Reverse engineering gives you a virtual copy of the original designer’s blueprint. If you can obtain a working model of an old product, you can easily trace the steps of its design to use those insights and construct a new model, repair a part or improve future products.

Today engineers use 3D scanning technologies to gain accurate readings of the product’s specs and have this information in their databases. 3D scanning technologies include coordinate measuring machines (CMM), industrial computed tomography (CT) scanners, laser scanners, and structured light digitizers.

The reverse engineering approach is commonly used in legacy parts replacement, service or repair of the product’s parts, failure analysis, and problem-solving. After all the applicable information has been gathered, it can be used to create computer-aided design (CAD) drawings for analysis and development.

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These engineers use the simulation tools to carry out their job responsibilities. To think like a simulation engineer you must be well acquainted with these 4 tools:

The Chainsaw: The tool cuts models into half and optimize them as per the project requirements. The tool is typically used for symmetric project models.

Virtual Reality: It simplifies difficult-to-mesh hardware that connects together in an engineering project. The technique removes unnecessary interference and allows designers to skip the meshing process for product design.

The Doctor: The tool checks the health of the project under development. Precisely, mesh health is checked in this technique comparing its aspect ratio against the desirable figures. 

Reverse 3D Glasses: The tool simplifies 3D models into 2D and 1D models making it easy for the simulation engineers to get an overview of the entire project.

A simulation engineer uses all these tools to develop a high-performance product. Hence, to think like a simulation engineer, you must look for techniques that reorganizes complex project details into smaller fragments which are easy to manage.

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Earlier the parts and equipment designed in the pre-CAD era caused problems in industries right from aerospace to power generation. Things that were designed without the benefit of CAD technology used to lack the critical documentation and information that was necessary for creating accurate models. Therefore, reverse engineering was essential in order to create CAD models needed by engineers and came into existence.

Understanding Reverse Engineering

Reverse engineering is a technology that helped in creating a three-dimensional virtual model of an existing physical part. Manufacturers made use of reverse engineering to deconstruct products or systems and evaluate, improve, or transform obsolete design information. However, now there are a number of optical measurement systems available for engineers today that are the best alternative to previous methods. Have a look at the tools that are now mainly used for reverse engineering:

Handheld Scanner

Traditional methods such as creating 3D models based on hand measurement and 2D drawing are expensive and time-consuming. Therefore, it became crucial to use 3D scanning for reverse engineering. Handheld Scanners can digitize 3-D surfaces and input relevant information into CAD systems. The tool is also famous to speed up the reverse engineering process.

CAD Design with SolidWorks

Solidworks is the most acceptable tool across the globe and helps in streamlining the design process by refining the existing designs or creating new ones. It can help in the development of 3D models, export to the 3D printer for the development of a prototype, or create molds.

Point Cloud

Point Clouds are developed by 3D scanners that measure huge points over the surface of an object and give the output in the form of a data file. Therefore, the point cloud is used in the creation of 3D CAD models in case of quality inspection, animation, visualization and for manufactured parts.

Geomagic Design X

The tool is built for converting 3D scan data to high-quality and feature-oriented CAD models. Geomagic Design X not only helps in creating feature-based models but also an editable solid model that is compatible with the existing CAD software. Also, it is the most comprehensive reverse engineering software.

HighRES Add-in for Inventor

It is highly compatible laser scanning software that is available today and functions to easily transfer scanned data for further enhancement. The tool can help in obtaining measurement data, convert it to a parametric CAD model, and has many more features. They are developed in order to support the current release of the respective CAD/CAM software.

Innovation for the Future

The aforementioned is the list of software that works for active development giving an emphasis on renewal and innovation. If you are looking for a partner who can assist you in reverse engineering tools, take up the Product Design using Reverse Engineering course from IID. Within the course, professionals with expertise in reverse engineering will help in your knowledge expansion and subject training.

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