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Tool and Die Reverse Engineering

Professional Outsourced Tool and Die Reverse Engineering Services

We constantly work with companies that have old tooling or dies that are used in injection molding, die casting, urethane casting, or blow molding. The problem is that every tool mold that you own has a specific lifetime, and it can only make so many parts before the quality drops off and you need to replace it.

How are you supposed to replace a piece of tooling that’s over a decade old? CAD/CAM Services can help. 

Our team can professionally reverse engineer your tools and dies, and we’ll create manufacturable 3D models and 2D manufacturing drawings. You can take these drawings, go to your machine shop of choice, and have brand-new versions of your tooling manufactured in no time.

We take all the guesswork and difficulty out of this process. Reverse engineering something as intricate as injection molding tooling could take multiple in-house engineers multiple weeks, and there’s no guarantee that the precision is perfect until you spend $100,000 making the tooling only to realize something is off.

Want to avoid wasting months and hard-earned money? You can trust CAD/CAM Services to simplify the reverse engineering process.


What Are Tool and Die Reverse Engineering Services?

Tool and die reverse engineering services entail taking your existing tooling, molds, and dies, and converting them into precise and accurate 3D CAD models. You can reverse engineer a part multiple different ways, but it’s hard to reliably and accurately get the measurements from your high-precision tooling using calipers or tape measures. 

Instead, our team uses state-of-the-art 3D scanners that cost a lot of money. These scanners are incredibly accurate, repeatable, and easy to use. Our team can reverse engineer an entire mold in a matter of hours, instead of days or weeks. 

With our unique approach, we can also give you a lot more confidence with every tool and die on your floor. We put every 3D-scanned image through a series of quality checks and peer reviews within our team to make sure everything is perfect before sending you the final models. We’ll look for defects in the 3D scan, or problems in the point clouds that we generated.

We do this to make sure you get the best results.

Why Tool and Die Reverse Engineering Services Matters

Recreating your old tools and dies is a massive undertaking. As you know, the manufacturing process can take months and over $100,000 — so it’s important that you don’t cut corners or take shortcuts during the reverse engineering process. Other outsourced tool and die reverse engineering companies might make assumptions or take the easier path, but that means a lower-quality 3D model that might not even work.

With CAD/CAM Services, you’re in good hands. We take a lot of pride in our work, and we want you to have CAD Perfect® reverse-engineered tools, molds, and dies. Our team goes the extra mile to make sure every model is absolutely perfect.

With a higher quality reverse engineering 3D CAD model for your tools and dies, the next version of your tooling will be much better and more reliable. With our high-quality 3D scanning services, we can make any adjustments to the final tooling in an effort to change the functionality of the parts you’re making. 

Allow our team to simplify and streamline the entire reverse engineering process.

Benefits of Tool and Die Reverse Engineering Services from CAD/CAM Services

People have been choosing CAD/CAM Services for over 35 years. Our 3D scanning services are among the best in the country, and people appreciate the extra effort we put into each project. There are a lot of reasons why you might choose CAD/CAM Services for your next tool and die reverse engineering project: 

A faster option.

Our reverse engineering teams can finish entire projects in hours or days, instead of the weeks it would take an in-house team of engineers to reverse engineer the same tooling.

Better quality with each tool.

We want you to have the highest quality in your tools, molds, and dies. This is why we go the extra mile to ensure every 3D CAD model and 2D manufacturing drawing is perfect for your reverse engineering project.

Access to expensive 3D scanners.

We own 3D scanners that are over $100,000. When you choose CAD/CAM Services, you can leverage these expensive metrology-grade 3D scanners to get better results.

Leverage a team that does it all.

Our engineers can handle reverse engineering, 3D scanning, 2D modeling, 3D CAD, point cloud generation, and dozens of other services. In other words, we can handle any engineering problem you run into.

More detail in every model.

Some of our 3D scanners are good enough to capture tiny cracks and engravings. That means more detail in every model, and better tooling for you moving forward.

What Goes into Tool and Die Reverse Engineering Services from CAD/CAM Services?

Our tool and die reverse engineering services differ from company to company. We want to provide as much value as possible to you, so we customize our services to meet your needs. For most projects, we’ll start with a consultation to understand what you have, what you need, what you’re looking for, and explain how we can help.

Our reverse engineering services usually entail taking a 3D scanner to your site and scanning your tooling, dies, and molds. Our engineers are 3D scanning experts, so we know the right way to generate 3D models from each 3D scan.

We’ll take the point cloud back to our office, generate a 3D CAD model in your CAD program of choice, and then go through quality checks across the entire model. We’re looking for tiny defects, issues with the scan, or details that need to be adjusted on the new tool or die model. 

After ensuring the quality is CAD Perfect®, we’ll generate 2D manufacturing drawings from the model. These drawings will be used by the machine shop of your choice to physically fabricate the mold, tooling, or dies.

Each drawing will go through a series of internal quality checks and peer reviews. After these checks, we’ll send everything to you through a DoD-trusted filesharing website to ensure your data stays secure.

Our Tool and Die Reverse Engineering Services Include:

3D Scanning

Reverse Engineering Services

2D and 3D CAD Modeling

Generating 2D Manufacturing Drawings

Engineering Simulations (like FEA), as Needed

And Much More (Including Custom Services)

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Get a Quote Today

If you want to iterate on an existing injection molding design, get an identical copy of old tooling, or adjust a die to improve the throughput of your process, CAD/CAM Services can help. We’ve been in business for 35+ years, and we have the skills, personnel, and equipment to offer high-quality tool and die reverse engineering for the most difficult parts.




Reverse Engineering FAQs
What is the average price for Reverse Engineering?

It all depends on the part’s complexity, size and structure.

What do you guys need to provide me with accurate pricing?

We need to know whether you need your parts to be scanned by us. Or many times we can work with 3D scans provided by third-party companies.  The quality of the scan is everything in our business. Anyway, we strongly advise you to use us for both the scanning and the CAD conversion aspects.  That way, we can control the quality. Sometimes we receive poor quality scans which make it impossible to create truly Cad Perfect™ models for you.  By all means, send us a couple of even cell phone photos, and the rough size of the object.  Most of the time, this will provide us enough information to provide a real bid.

The price depends on the part complexity, size, as well as the target file parametres. We need to know whether you need full parametric models, and your desired accuracy. If you tell us the purpose of reverse-engineered models, we can often provide you with possible solutions. The target CAD software may change the price as well. This includes sophisticated Workstation add-on products such as Composites, Catia electrical wiring, mold design, and others.

What is the quality of reverse-engineered parts?

We can provide ±.005” aerospace quality for every model. CT scanned parts can have even higher precision up to ±.001”.

3D Scanning FAQs
How much does scanning services cost?

It depends on the complexity of the scanned model and material properties. As, for example, it may be much more complicated to properly scan an object with a reflective surface, than a non-reflective surface. It also depends on three main factors:

  1. the physical size of your part
  2. the required scanning resolution
  3. if industrial CT or metallurgy scanning is needed

Simple quick cell phone photos are worth a thousand words to us. To know for sure you can request a quote. It is of course, free – and treated as if an NDA is already in place.

Some averages:

  • The typical 3D scan is somewhere around $200-400 per part.
  • Tomographic (CT) scanning is $600-900 per part.

Because so much of our business is Aerospace related, our scanning – and the completed CAD file HAS to be within ±.005” anywhere on that part, we never use consumer-grade scanners. The scanners we use start at $25,000 and go up to $700,000 (CT) per scanner.

At any given time, we have in excess of $ 5 million just in scanning hardware we use. In addition, a hidden factor of scanning on any system is the assembly and clean up of any scan. The rule of thumb is a 2-1 ratio. So even with our experienced scanning staff, if we spend one-hour scanning; we will then spend an additional two hours of clean up and assembly before our CAD group gets the Point Cloud file to simulate or reverse engineer.

What is the Point Cloud/Mesh/3D Scan?

A point cloud is thousands if not millions of data points located in space by X, Y, Z coordinates. Images of this nature are often captured with Faro Focus or Artec scanners that specialize in large-area scanning.  Most likely you obtain building and territory plans in this file format.

A polygon mesh is a set of triangles located in the same manner. These scans are obtained with Artec, Creaform, Enscan and other handheld scanners. Parts and reverse engineering device scans are usually polygon meshes.

What types of scanners do you use?
  • Faro Arm – Very good for most parts, fast and accurate
  • Turntable scanners – high accuracy, high detail, fast scanning. Great for smaller parts.
  • Portable handheld – may be favorable for some larger parts – if not a tripod-mounted scanner.
  • Long Range – these mount on a tripod, and are intended to scan buildings, plants, and other larger sized projects.
  • Industrial CT scanners – incredibly expensive, but they offer two main benefits – the ability to inside an object (think of a void in a solid object), and their accuracy.  At this level, we are often in the ±.001” – ±.002” range, and often used in metrology scanning.

Which scanner models do you use?
How accurate is 3D scanning?

The scanners we use are as accurate as the industry offers – from anybody at any cost. We use Faro and Artec 3D scanners, in addition to Faro CMM type arms, including the Surveyor tables. Depending on what scanner we use:

  • CT scanners – 4 to 400µm/voxel resolution
  • Artec Portable scanners high accuracy (0.03 – 0.05mm)
  • Artec Portable scanners high resolution (up to 0.15mm)
  • Our CyberGage 360 – generates highly precise full 360 degrees automated scan with accuracy NIST traceable to approximately 7 microns
  • The CyberGage 360 has a system repeatability of ±.005mm.
3D Modeling FAQs
How do you bill 3D CAD services tasks?

Per hour. Hourly rate depends on what CAD software used and typically starts at $75 per hour.  In general, to make this process safer for you, we often provide you a fixed not to exceed the cost as well.  That way, you are protected from an open-ended PO. However, the reality is our fees are based on time. In addition, services in say Catia or NX are more expensive than say Solidworks. Or, simulation services are commonly done by real engineers.

What do you need to give me accurate pricing?

First of all, we need to know the target CAD system and whether you have an existing  template, or set of CAD standards for this project.

The main question is the overall complexity. As each part and assembly consists of different features and elements the best way is to provide us with an example.  Again, a picture is worth a thousand words.

If you already have a model and need us to improve it or update it in any way we need to know which dimensions and features are critical and which can be modified to achieve your desired result.  Even a before and after example works very well. We started with x, and got to this CAD file.

We can also offer you better options if you provide us with the purpose of your project (demonstration, 3D printing, FEA Simulation, CNC manufacturing, etc.).  This helps us better refine the task.

How do you check your models?

We create 2D drawings from our 3D models for QC purposes. We follow aerospace standards and deliver ±.005” accuracy models for all projects.  All of our QC is done by a different person than the designer. On Catia work, we often use Q-Checker for Airbus.

What is the minimum price for your 3D modeling services?

We have a minimum order fee $150.

General CAD Questions
How do I send a sample, in order to get a quote?

Fill out our quote form, attach your files, or simply send us an email. Tell everything about your project, like the model purpose.

For smaller files < 15 MB you can simply email them to us.  For something larger, just drop them in any number of drop boxes like Dropbox, Google Drive, Microsoft OneDrive and others.  Or if you would like, just contact us for a private, hardened link.

It is fine to use most any time of compression such as  *.zip, *.rar, *.tar, *.7z, *.arc, *.LBR, and even *.iso images.

A direct email is [email protected]

We also use a hardened OwnCloud web file sharing platform for unlimited file transfers. We provide unique and very private Web Storage Portals, this also supports file syncing for extreme convenience for you. Because so much of our work is DOD or weapons design work, Security – and confidentiality is very important to us.

Will CAD / CAM Services Sign a Non-Disclosure Agreement (NDA)?

Yes. NDAs are a common part of our business. All data is yours – not ours, and treated as proprietary data and not for public consumption or use. Probably 70% of our work is under NDA agreements. We can generally get these signed within the day.

What is the estimated delivery time?

It depends on the scope of work:

  • 2D drawings – small quantity, normally 48 hours.  We have several customers where they contract to us, keeping 4-8 drafters busy full time.
  • 3D models – complexity dependent, but smaller jobs in 2-3 days. Some models we have spent months on.  Again, we have several customers where they contract to us, keeping 6-10 3D CAD designers busy full time.

Simple jobs have a lead time of 48 hours. Larger projects are delivered and invoiced weekly.

Did you really own the trademark Cad Perfect™, Cad Perfect CAD Conversions™ and Cad / Cam Services™?

Yes, we did back in 2008. We started using Cad Perfect™ back in the early 1990s because all of our customers wanted only real Cad Perfect™ work. Back then the buzz words were terms like machine ready, or DXF Traceover and others.

The problem is, nobody wanted that. They all wanted drawings and models that they did not have to touch. Everybody wanted drawings just as if they hand redrew the work themselves.

Thus, Cad / Cam Services™ was the first company to start offering ONLY Cad Perfect™ work.

Do you support the PPD-21 Directive?

Yes we do, and have now for several years. In addition, we also support the industry specific plans as well.