Reverse Engineering Services
3D scanning. CAD reconstruction. Physical part recreation. Engagements include 3D scanning services, CAD reconstruction, and related work — all under NDA.
Overview
Mechanical reverse engineering services with precision 3D scanning and CAD reconstruction. Recreate legacy parts and document mechanical assemblies.
Engagements are scoped to a fixed deliverable list before kickoff and run under a written NDA. Daily lab notes and weekly written status keep the work auditable from your side at every step.
In the lab
Scan, parametrize, verify against the sample — together.
Mechanical RE Lead
Anonymized pre-NDA
How we work
In both reverse engineering and custom development, we never thoughtlessly clone. We carry out improvements and adaptations to the customer's specific task, because the existing solution often cannot fully satisfy the customer's request. Reverse engineering surfaces the design intent; the engineering that follows decides what to keep, what to change, and what to engineer from scratch.
Engineering analysis
As part of both reverse engineering and custom development projects, we perform in-depth engineering analysis based on mathematical and physical modeling. Depending on project requirements this may include structural calculations, fluid dynamics, gas flow analysis, thermal processes, stress and load simulations, process modeling, and validation of engineering assumptions affecting system performance and operational reliability — used for design verification, technology assessment, process optimization, and validation of technical parameters for production and commercial deployment.
When you call us
Patterns we see across engagements. Each can stand alone or combine with adjacent capabilities.
Recreate manufacturable CAD and drawings for legacy mechanical components when original design files are lost or unavailable.
Capture as-built geometry of complex assemblies with structured-light or laser scanning. Foundation for inspection, comparison, and CAD recovery.
Convert scan data and physical measurement into parametric CAD with proper feature trees — buildable, editable, manufacturable.
Manufacture replacements for OEM parts whose vendor is gone. Output: fully toleranced drawings and a qualified manufacturing path.
Compare as-shipped parts against design intent or against a golden reference. Useful for supplier qualification and field-failure investigation.
Bring physical prototypes back into CAD for digital iteration. Common in industrial design, consumer products, and aftermarket development.
Establish geometric dimensioning and tolerancing on parts that were originally drawn with limited tolerance specification.
Methodology
Vertical phasing — each step's deliverables agreed before kickoff, and not closed until you sign off.
Phase 01
Mutual NDA executed before any sample, drawing, or technical materials change hands. Scope, deliverables, and chain-of-custody terms confirmed in writing.
Phase 02
Sample receipt, photo log, and target deliverable definition. Decision on contact vs. non-contact metrology and scan resolution.
Phase 03
Structured-light or laser 3D scanning, supplemented by CMM measurement for critical features and CT scanning for internal geometry.
Phase 04
Cleanup, alignment, and meshing of raw scan data. Production of inspection-ready surface mesh.
Phase 05
Conversion of scan data to feature-based CAD in SOLIDWORKS, Fusion 360, or your preferred package. Editable feature trees with proper constraints.
Phase 06
GD&T-compliant 2D drawings with derived tolerances. Material identification and surface-finish specification where applicable.
Phase 07
Comparison of reconstructed CAD against the original sample with deviation maps and a written acceptance report.
Tooling
Named tools, in production. We don't list anything we don't actually use.
Tool
Structured-light 3D scanners
Production use — versioned per-engagement and pinned in our build.
Tool
Laser line scanners
Production use — versioned per-engagement and pinned in our build.
Tool
Coordinate Measuring Machines (CMM)
Production use — versioned per-engagement and pinned in our build.
Tool
Industrial CT scanning
Production use — versioned per-engagement and pinned in our build.
Tool
SOLIDWORKS
Production use — versioned per-engagement and pinned in our build.
Tool
Geomagic Design X
Production use — versioned per-engagement and pinned in our build.
Tool
Fusion 360
Production use — versioned per-engagement and pinned in our build.
Tool
PolyWorks Inspector
Production use — versioned per-engagement and pinned in our build.
Tool
Point cloud processing pipeline (CloudCompare, Geomagic)
Production use — versioned per-engagement and pinned in our build.
$ atos scan --target part-a.stl --resolution 0.05mm
Captured 4.2M points · mesh closed
$ design-x recover --reference part-a.stl --output part-a.x_b
Reconstructed parametric model · 22 features · 1 sketch failed
$
Deliverables
Artifacts handed over at close-out. Each is reproducible and self-contained.
Sample deliverable
mechanical-reverse-engineering · final report
rev.04 · pdf
Engagement summary
Findings
Our practice
Mechanical work pairs metrology with engineering interpretation. We capture, we reconstruct, we derive GD&T — and your team approves the tolerance scheme before drawings finalize.
Metrology to drawings
Structured-light capture, CMM reference, parametric reconstruction — drawings ready for manufacturing.
Mechanical RE Lead
Anonymized pre-NDA
Metrology Engineer
Anonymized pre-NDA
CAD Reconstruction
Anonymized pre-NDA
GD&T Specialist
Anonymized pre-NDA
“We deliver parametric CAD with a feature tree your team can edit — not a frozen STL.”
Cross-industry
Sectors where this work is most often scoped. Cross-link to detailed industry pages for sector-specific context.
PLC and legacy controller recovery.
Mechanical RE for industrial & manufacturingSustainment for long-life platforms.
Mechanical RE for aerospaceECU, CAN, and aftermarket interoperability.
Mechanical RE for automotiveCompliance-aware reverse engineering.
Mechanical RE for medical devicesQuestions
Pulled from real client conversations. If yours isn't here, ask directly.
Our mechanical reverse engineering services cover the path from a physical part to a manufacturable CAD model and drawing set. The work includes 3D scanning, dimensional analysis, parametric CAD reconstruction, GD&T derivation, and verification against the original sample. Output is buildable in your preferred CAD format.
We use structured-light and laser line scanners for general geometry, CMM for high-accuracy critical features, and industrial CT for internal geometry. Scanner choice is driven by the part: surface complexity, size, finish, and the tolerance the deliverable needs. The scanning rig is selected during scoping.
Yes — manufacturable, parametric CAD with proper feature trees is the standard deliverable. We avoid 'dumb' surfaces. The CAD model your team receives is editable, dimensionable, and ready for downstream engineering work, not just an STL of the scanned mesh.
Tolerance accuracy depends on metrology choice and is set during scoping. Structured-light scanning typically achieves 25-50 µm accuracy; CMM measurement reaches single-digit microns on critical features; CT scanning produces internal geometry with similar accuracy. The deliverable includes a written accuracy budget.
We offer on-site scanning for large or delicate parts — common for aerospace assemblies, large industrial equipment, and historical artifacts. Our portable scanning rigs travel to your facility under chain-of-custody documentation. Output is identical to lab-based work.
Yes. Single-sample work is common, particularly for legacy and discontinued parts. We bias toward non-destructive techniques and produce a deviation map showing how confident we are in each region of the recovered geometry.
Yes. GD&T derivation is a sub-deliverable for sustainment programs. We measure the part, identify the functional features, propose a tolerance scheme that reflects how the part is used in assembly, and document the rationale. Your engineering team approves the scheme before drawings are finalized.
Yes. We deliver in SOLIDWORKS, Fusion 360, Creo, NX, or neutral STEP / IGES formats. Drawings follow ASME Y14.5 or ISO 1101 GD&T conventions per your standard. The CAD model is yours under your preferred license posture.
Engagements start with a scoping phase under NDA. Project length and pricing depend on part complexity, required accuracy, deliverable depth, and whether on-site scanning is required. We offer fixed-bid scopes for well-bounded recovery work.
Selected work
Engagements where this pillar carried significant scope.
A family of press molds designed and manufactured for forming facing products by semi-dry pressing on a cement binder. Calculated pressing force: 300 kg/cm². Standard, semi-standard, Bavaria, and Saxony-corner geometries — every die tuned for sustained cement-binder abrasion, not catalog peak.
Read case studyA fully automated heat-and-humidity curing chamber for cement-bonded hyperpressed bricks. Designed to bring product strength to near-complete cure within an 8-hour cycle, with a heat recovery zone that materially reduces energy demand per cycle.
Read case studyA complete mechanical engineering workshop designed, specified, and established — 600 m² of full-cycle steel processing capacity dedicated to producing tooling for a facing-brick and -tile semi-dry-pressing line. Owned from process design through layout, equipment selection, infrastructure spec, and staffing structure.
Read case studyMore from us
Adjacent capabilities you may need on the same engagement.
Engage
All inquiries reviewed under NDA. We respond within two business days with a scoped engagement plan and fixed deliverables list.
Senior engineers · Anonymized pre-NDA
