Do you want to invest in new equipment for reverse engineering and you aren’t sure what to buy?
Reverse engineering requires specialized tools and equipment to meet the broad needs of companies and individuals across a wide range of industries. The first, and one of the most essential, specialized pieces of equipment is the scanning technology. Different scanners are used depending on the requirements of the subject being reverse engineered.
From there, the specialized software brings the scanned data and processes it into a model. Technicians can evaluate and manipulate the model to decrease any error. Finally, the file containing the model is sent to production using the right machinery for the job.
So, what equipment do you need to get started? Keep reading to learn 6 essential tools and equipment for reverse engineering.
6 Essential Tools and Equipment for Reverse Engineering Success
There are two types of 3D scanners that are commonly used for reverse engineering. Non-contact 3D scanners are laser or structured-light 3D scanners and contact 3D scanners work by using a contact probe. Portable CMMs and optical CMMs are examples of contact 3D scanners. Let’s discuss each type in more detail.
1. Non-Contact 3D Scanners
Non-contact 3D scanners haven’t been around as long as contact 3D scanners. They are great tools for measuring when you need to collect more data from the object to reverse engineer it. A snapshot is captured of the surface measurements in one scan. One million 3D coordinate points can be captured per one second with a structured-light 3D scanner.
Non-contact 3D scanners are great for capturing complex surfaces such as organic and freeform shapes. They are also an excellent choice for antique or fragile objects that shouldn’t be touched. The downside is that it takes more time collecting the data compared to a CMM, and objects with shiny, dark, or reflective surfaces will be difficult to scan. A workaround for the latter is coating the object with a non-reflective, light-colored paint before scanning.
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2. Contact 3D Scanner: Coordinate Measuring Machines (CMMs)
CMMs come in a few varieties. Some are optical scanners and are considered no-contact measuring. Others have a probe that touches the object to take measurements. CMMs can collect a large amount of accurate data, but they are much slower than other methods. CMMs can also be affected by some environmental factors, but those can be avoided in most cases with proper planning.
The data from CMMs are a cloud of points that are then run through special software. The software interprets all the points into a model that can be analyzed for errors and tweaked to correct any issues. The additional time and accuracy mean this method is more expensive than other forms of laser scanning, but the increase in price may be worth it given the geometry of the object.
Recommended Reading: Steps Involved in Reverse Engineering a Part
3. Computed Tomography (CT)
CT scanning is one of the most accurate technologies available today, especially when it comes to reverse engineering. CT scanning uses x-rays to collect data from the external and internal measurements. It’s relatively fast, it doesn’t require the object to be physically broken down, and the scanned object is unharmed.
The ability to take internal measurements can make this option a no-brainer compared to some of the other choices. It can be challenging to get those measurements with other methods. CT Scanning is more expensive because the cost of creating strong x-rays and necessary safety for technicians is not low. Especially if you are dealing with thicker or heavier metals. Some of the capabilities of this method, however, make it well worth the additional cost.
Long-range scanning has a different application than most of the methods already mentioned. Long-range scanning gives you the ability to scan extremely large objects such as buildings, bridges, or entire machines. This method can be used to collect data even in poor conditions — such as low light. The data is pretty accurate and can be used to generate things such as blueprints.
These are just a few of the options available — and technology is always advancing and inventing new methods.
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4. The Right Software
Specialized software is used to interpret the data that is collected by scanners. The job of the software is to take a cloud of data points and connect them together to form a digital model of the original object accurately. The model can be loaded into a CAD program for adjustments next.
In most cases, the software also does error analysis. A trained technician can interpret the analysis to identify areas where checking and tweaking might be needed or useful. Most of the models allow for reasonable effort in making the modifications, though a few are quite challenging.
After the digital model has been finalized, it can be saved into several different file formats depending on the requirement of the final production of the new item. For example, the model may be saved as an STL file if it were going to be sent to a 3D printer.
Recommended Reading: How Detailed Are Reverse Engineered Parts?
5. Production Machinery
The production methods used for reverse engineering are the same that are available for machining a new design. 3D printing can be used for the rapid production and prototyping of a part. Milling, die casting, and even laser cutting can even be used. Each machine has pros and cons given the object and the material you want it made out of.
6. A Trained Staff
Are you ready to purchase equipment, but you still aren’t sure what to buy? Or maybe you’re considering outsourcing the work instead. Which one is more cost-effective, and what would be the better fit? Our team of highly skilled engineers can help! We go the extra mile to build long-lasting relationships with our customers, and we are here to give you the advice you need to make these tough decisions.
“Over the past five years, I have been working with EMS, everyone has gone out of their way to be very helpful and courteous. You all really have the customer’s needs in mind. Not only are you willing to take on difficult projects, but you make it seem easy. You really have a great team there.” — Design Engineer from Phoenix USA™, Inc.
Contact us and consult with a member of our team if you aren’t sure what route is best for you and your company.
Do you think outsourcing the work would be a better fit? Check out our services page to find out more about how we can help you with your reverse engineering needs: Reverse Engineering Services.