The impact of reverse engineering on the acceleration of innovation
Reverse engineering: How it works and what it changes
In a world where innovation progresses at a swift pace to meet ever-evolving needs, reverse engineering plays a key role. This process involves the use of tools and software that enable in-depth analysis of the design, manufacture and operation of complex products and systems. All without first having access to the information stored in their documentation. When CAD files are not available, 3D scanning of an object or model can be used to retrieve exploitable data in digital form. These scanners make it easier to reuse and improve old objects, optimising innovation in terms of design and cost.
When reverse engineering becomes a driver of innovation
Reverse engineering is a key lever in various fields, enabling the development of improved products compared to existing designs. It makes it possible to manufacture obsolete parts and optimise computer aided design processes in areas such as the automotive, rail and aerospace industries.
What is its practical impact ?
Reverse engineering applies as much to physical parts (automotive device, mechanical component, electronic circuit), as to intangible elements such as computer source code. By disassembling the object, whether virtual or material, the engineer gains access to its internal structure using tools (scanners, microscopes, software, etc.) and is able to carry out an analysis of each of its constituent components. After analysing the object, they can then go back to engineering decisions and start manufacturing a new product by updating its characteristics. This process considerably speeds up development, reducing production costs while optimising the quality of the final product and the time spent on it.
Stimulating CAD through reverse engineering
One of the aims of the reverse engineering process is to digitise a physical model into a computer-aided design (CAD) file can be used in a system such as Siemens NX CAD software. The use of this software enables the technical information about the part or object analysed to be restored, in order to recreate documentation that facilitates the design of its computerised design. We therefore move from a physical object to its digital equivalent visible on CAD software via 3D scanners.
Software like Siemens NX offers the functionality of importing data in the form of facets from 3D scans. Using reverse engineering before embarking on the redesign of a model in CAD software allows, on one hand, the possibility of manufacturing obsolete parts and, on the other hand, the ability to use alternative components and modifications to optimise the weight, cost, safety, and performance of the product.
After revealing the 3D model, the engineer proceeds to an analysis of its deficiencies thanks to a colour deviation map that highlights deformations and missing parts. In the automotive industry, it is widely used for manufacturing spare parts, scanning old models and studying the competition. The aerospace industry is also involved, particularly for the manufacturing of tooling and the development of maintenance plans. It is also used for restoring art and preserving historical objects. However, while transitioning from a 3D scan to a 3D model usable in computer-aided design represents a real innovation for the CAD market, these analysis and design techniques require highly skilled engineering expertise.
How it works in action when using Siemens NX ?
See how reverse engineering takes shape in NX CAD in this video.
Challenges and ethical considerations
Time and cost optimisation, interoperability between different CAD systems, adaptation of existing designs, identification of weaknesses and distortions are just some of the benefits of reverse engineering. However, it is important to emphasise these 3 points before embarking on the reverse engineering process:
- The cost of 3Dscanners: 3D scan analysis to gather all the information and data on CAD software represents a budget. The scanners that enable documentation to be imported electronically are equipped with specialised sensors (structured light 3D scan, laser pulse 3D scan, contact 3D scan, etc.);
- CAD modelling errors and misinterpretation of retrieved data: reverse engineering requires expertise and technical skills from the engineer, who must know how to make correct use of the data and information gathered;
- Intellectual property rights: Reverse engineering raises intellectual property issues, since it enables information on external models and objects to be collected and used. However, it also offers companies the opportunity to create detailed documentation for their own products. In this way, designing models in CAD software enables the input of proprietary digital data to defend against counterfeiting or copying after production.
Reverse engineering is therefore a powerful tool that accelerates innovation by optimising design processes and effectively exploiting data from existing objects for which there is little or no digital data. With the evolution of technologies such as 3D scanners and CAD software, it promises to further transform industry by making innovation faster, more accessible and more sustainable.