Products can be reverse engineered for more durable and reliable alternatives with faster and more cost effective manner. Reverse Engineering begins with the Product either to modify or to enhance the original product. Reverse Engineering is the process of producing design details in the form of cad model from the physical part. The process of duplicating an existing component, subassembly, or product, without the aid of drawings, documentation, or computer model is known as reverse engineering. Reverse Engineering is recovering part geometry from the physical sample. The geometry recovering process consists of two steps scanning to capture the part geometry in discrete points and converting points into useful surface forms. The geometry can also be captured by mapping the surface with a laser scanner & full contact CMM laser scanner by a process called capturing geometry internally.
Input to Reverse Engineering process comes about in three ways namely scanning a physical artifact with lasers or applicable technology, analyzing drawings for geometry and performing variety of engineering analysis to determine appropriate reverse engineering specifications.
In some situations, designers give a shape to their ideas by using clay, plaster of Paris, wood, or foam rubber, but a CAD model is needed to enable the manufacturing of the part. As products become more organic in shape, designing in CAD may be challenging or impossible. There is no guarantee that the CAD model will be acceptably close to the sculpted model. Reverse engineering provides a solution to this problem because the physical model is the source of information for the CAD model. This is also referred to as the part-to-CAD process. Another reason for reverse engineering is to compress product development times. In the intensely competitive global market, manufacturers are constantly seeking new ways to shorten lead-times to market a new product. Rapid product development (RPD) refers to recently developed technologies and techniques that assist manufacturers and designers in meeting the demands of reduced product development time. For example, injection-molding companies must drastically reduce the tool and die development times. By using reverse engineering, a three-dimensional product or model can be quickly captured in digital form, re-modeled, and exported for rapid prototyping/tooling or rapid manufacturing.
The process consists of first scanning the object concerned to create a point cloud that represents the skin of the object. Representing geometry of the part in terms of surface points is the first step in creating parametric surface patches. The point''s coordinate location is stored as part of a point cloud representing the physical part. Millions of points are collected this way until the entire surface of the part or object has been digitized.
The digital data (collectively called a point cloud) is used for Reverse Engineering, Rapid Prototyping, and Product Inspection. A good polymesh is created from the point cloud using reverse engineering software. The cleaned-up polymesh, NURBS (Non-uniform rational B-spline) curves, or NURBS surfaces are exported to CAD packages for further refinement. Then using a cad software surface model of the object is created. The surface model thus created is exported to solid modeling.