How do we define reverse engineering?
The practice of building a project out of parts or goods without any blueprints or documentation is known as reverse engineering, also referred to as back-engineering. These components can be altered and optimized via 3D scanning to create a digital CAD model, extending their lifespan or enabling additional functions, a practice Promedia Systems, a Solidswork Reseller in UAE has heavily adopted. Numerous companies, such as those that produce military hardware or spacecraft, employ this technique.
Reverse engineering is receiving more and more attention as 3D printing becomes increasingly widespread. This is because compared to traditional production methods, digital modeling and 3D printing make it easier for regular consumers to reproduce an object or design.
Obtaining a sufficiently accurate digital impression of a part, turning the resulting image into a solid 3D model using specialized software, and finally digitally processing the model to remove artifacts, change the format, and make some modifications so that the model design is appropriate for the product launch are the three steps involved in reverse engineering.
To collect the fundamental data that best meets the current work, it is therefore essential to select the appropriate 3D scanner from professionals like Promedia systems, a trusted SolidWorks Resellers in UAE. For instance, scanning a piece of jewelry with a time-of-flight scanner meant for huge objects is absolutely worthless, and vice versa: the extremely high accuracy of a desktop or mobile scanner is unnecessary when scanning, say, a ship.
Reverse engineering stages
Step 1: Get the object ready for scanning; use markers if required. Spray a temporary matte powder on the object to improve scanning accuracy. Glossy surfaces hinder the work of 3D scanners and reflecting or transparent ones are practically impossible to scan without a matte finish.
Step 2: Scan key sections of the part with a 3D scanner. If your object has holes or deep grooves, you might need to reorient and scan it numerous times.
Step 3: Modify and improve the generated polygonal mesh. Some scanners produce very huge files, which makes it challenging to edit and print an object. Check the surface stitch and remove any artifacts.
Step 4: Add the mesh to a CAD program that has tools for reverse engineering.
Step 5: Convert polygons to solids
Step 6: If additional objects are required, add them to the final 3D model or remove those that are not required.
Step 7: Using CNC or 3D printing technology, design a new part based on the produced model.
Case studies
Impeller reverse engineering
A maker of equipment is needed to optimize impeller production and get rid of manufacturing inconsistencies. By using conventional methods, it proved impossible to get precise data on a part having holes, dead angles, and geometrically complex surfaces. Since measuring the impeller with a probe would be impossible due to its small gaps between the vanes, it was decided to use 3D laser scanning and analyze the data using reverse engineering techniques for comparison with the original digital model.
The ScanTech PRINCE high-precision 3D scanner with red and blue laser scanning modes was used to accomplish the 3D scanning. The device can quickly switch between modes and has a resolution of 0.020 mm. With a single red laser line, it can scan deep holes while collecting even the finest details. The scanner is also unresponsive to outside light.
Reverse engineering a speaker cart to make audio
A captain had to do something for her squad in order to take part in the sports and dance competition known as Colorguard. She made the decision to build a cart to hold the bulky speaker that the girls use to play music while practicing and performing. If necessary, the speaker may be quickly removed from the cart. Additionally, one of its handles needed to be restored.
Three identical handles are screwed onto the speaker. The EinScan-SP was used to scan one of the remaining handles in order to replace the broken one with a new one. The handle was quite dark, so it was lightly powdered with baby powder to make the surface visible to the scanner. When an object is rotated on a turntable and in various positions, the EinScan-SP has the ability to automatically stitch images together. From a number of scans, the computer chooses certain locations and joins them. Users are able to scan the object’s top and bottom in addition to its sides thanks to this.
The Deform: Smooth tool in the free Autodesk Meshmixer program was used to remove any damage to the handle and clean up the resulting image of artifacts. The event logo was added after the manufacturer’s logo was deleted using the Edit: Erase and Fill tools. To guarantee that the screw holes were cylindrical, a meshmixer was also employed. The model was simplified and the file size dropped from 26 to 2.4 Mb after the STL file was processed in Meshlab.
Conclusion
Even more process automation is what reverse engineering will look like in the future. Manufacturers are increasingly using the capabilities of cloud and artificial intelligence in scanning and post-processing to let novice customers complete their work on their own. Specialists in a range of industries, such as doctors scanning body parts or employees on building sites, may find this handy. The consumer market for 3D scanners is expanding, and they may soon be as prevalent as smartphone cameras (some of them are already equipped with a ToF sensor).
Contact Promedia systems, a trusted work SolidWorks Reseller in the UAE for your best 3D Scanners and more. Get your work done in the most professional way possible.
