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Reverse engineering in Poland based on metrology-grade 3D scanning is used to reconstruct parametric CAD models from point clouds/meshes when documentation is missing or unreliable. Typical outputs include CAD formats (STEP/IGES/Parasolid) plus dimensional verification (CAD vs scan deviation maps) for engineering and manufacturing workflows.

Reverse engineering is generally performed on parts and assets owned by the client or on objects where documentation is not available. In industrial practice, it is commonly used to restore maintainability, support modernization, and create engineering documentation for legacy assets.

Legal and practical scope

Reverse engineering projects can involve very different objects, but the engineering pattern stays the same: measure → reconstruct → verify → deliver.

Automotive modification and fitment (underbody and assemblies)3D scanning of complex, hard-to-measure areas (e.g., underbody, cargo area, engine bay) is used to obtain real geometry for redesign and custom components. Metrology-grade scanning enables reliable CAD work without “guessing” geometry.

Consumer/industrial product reconstruction (waste container CAD model)When internal geometry matters (e.g., contact surfaces, volume-dependent processes), scanning focuses on interior surfaces and functional areas. CAD reconstruction typically removes local defects present on a specific sample to create a functional reference model for engineering teams.

Dimensional control is recommended and can be performed at two levels:

1) Digital verificationCAD model is compared to scan data using deviation maps (color maps), section cuts, and point-wise measurements to evaluate:

geometric differences,
local deviations and their engineering significance (defects vs features),
tolerance compliance.

2) Physical verificationIf a new part is manufactured, it can be re-scanned and compared to the reference (original scan and/or CAD model) to confirm conformity.

This approach keeps reverse engineering outcomes auditable and engineering-grade.

Example reference cases (engineering logic, not portfolio)

Verification and quality control (CAD vs scan)

Reverse engineering produces measurement data and engineering models. Typical outputs include:

After scanning (measurement data):

Mesh formats: .stl, .obj, .ply
Point cloud formats: .e57, .pts, .xyz, .ply

After CAD reconstruction (engineering models):

CAD/neutral formats: .step, .iges, .x_t (Parasolid), .dwg(Chosen to maximize interoperability across engineering environments.)

Deliverables are selected based on how the receiving team will use the data (design, manufacturing, simulation, inspection).

Deliverables and file formats

Reverse engineering quality is limited by measurement quality. INNOVAR performs metrology-grade 3D scanning using systems with:

local (point) accuracy up to 0.02 mm,
volumetric accuracy (VPG) 0.046 + 0.012 mm/m,
compliance with VDI/VDE 2634 (as referenced in measurement certification workflows),
accuracy confirmation from an ISO/IEC 17025 accredited laboratory (as a verification basis for metrology-grade use).

For large-scale environments and spatial systems, long-range laser scanning is used where millimeter-level tolerances are appropriate.

Measurement capability and accuracy (what the data can support)

The detailed workflow depends on the objective (fitment vs redesign vs production), but the structure is consistent:

3D scanning (laser or optical, depending on tolerance and geometry)
Point cloud / mesh processing (cleaning, alignment, registration)
Retopology and CAD reconstruction (surfaces/solids, feature extraction)
Dimensional verification and tolerances
Data delivery for manufacturing or further analysis

Key engineering principle: the goal is not visualization. The goal is measured geometry usable in CAD.

Methodology: from scanning to CAD

Reverse engineering is applied in manufacturing, machinery, and automotive when the project depends on real geometry rather than nominal drawings. In Poland Common cases include:

recreating parts without technical documentation,
modernization and optimization of components and assemblies,
fitment and collision analysis for new elements in existing systems,
quality control (comparison against a nominal CAD model),
preparation of CAD models for CNC manufacturing or 3D printing,
R&D workflows (e.g., FEM/FEA) based on measured geometry.

Typical use cases in Poland

In engineering workflows, reverse engineering means transferring a real object into a controllable digital form:

measurement of the object (3D scanning selected according to required tolerances),
creation of a point cloud and/or mesh (triangulated surface),
reconstruction of a parametric CAD model (surfaces/solids),
dimensional verification (CAD vs scan comparison),
delivery of manufacturing-ready and analysis-ready data.

In some cases, a scan mesh alone can be sufficient (e.g., for direct 3D printing of geometry-only parts). However, most industrial applications require a CAD model—editable, constrained, and compatible with standard engineering software.

What “reverse engineering” means in engineering projects?

Reverse engineering (reverse engineering based on 3D measurements) is the process of reconstructing geometry and functional features of an existing physical object from measurement data—most commonly from 3D scanning—in order to obtain CAD documentation, modify a design, or perform technical analysis.

In industrial practice, reverse engineering is typically used when technical documentation is missing, outdated, or unreliable, and the project requires verifiable geometry for manufacturing, modernization, or fitment of new components to existing assemblies.

This page focuses on reverse engineering of physical objects, not software analysis.

Reverse Engineering in Poland – From 3D Scans to Engineering CAD Model

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