Reverse Engineering Services — Scan to CAD, ±.005" Accuracy

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.

Reverse engineering is the process of analyzing an existing physical object, product, component, assembly, or system to understand its design, dimensions, materials, and functionality so it can be recreated, modified, documented, or manufactured again.

In the CAD and engineering world, reverse engineering typically involves converting a physical part into accurate 3D CAD models, 2D drawings, and engineering documentation.

We often:  1) Capture Existing Data by 3D scanning, 2) create a Digital model, often called a Point Cloud, 3) build a 3D model, and 4) produce the required engineering documentation.

Typical Accuracy Ranges

Hand Measurements (Calipers, Micrometers) ±0.001" to ±0.010"

Structured Light Scanning ±0.001" to ±0.005"

Laser Scanning ±0.002" to ±0.010"

Photogrammetry ±0.010" to ±0.100"+

CMM Measurement ±0.0001" to ±0.001"

Hybrid Scan + CMM Validation ±0.0005" to ±0.002"

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For aerospace, medical, and precision manufacturing applications, a combination of 3D scanning and CMM inspection is often used to achieve the highest accuracy.

Also, there can be two parts to this answer: 1) The accuracy of the scanner, and then 2) if we are going all the way to an editable feature-rich CAD file.  If we are going all the way to the CAD file, we are within ±.005” of any Point Cloud data.

Many people use the terms 3D scanning and reverse engineering interchangeably, but they are not the same thing.

3D scanning is the process of capturing an object's geometry. Reverse engineering is the process of converting that captured data into usable engineering information, such as CAD models, drawings, and manufacturing documentation.

Simple Explanation

Think of it this way:

• 3D Scanning = Data Collection = a picture of 1,000,000 dots in 3D space
• Reverse Engineering = Engineering Reconstruction = a feature rich, editable CAD Perfect® CAD file.

A 3D scanner captures the shape of an object. Reverse engineering transforms that shape into an intelligent, editable CAD model that engineers and manufacturers can use.

Yes. Reverse engineering obsolete parts is one of the most common reasons organizations pursue reverse engineering services.

When original manufacturers no longer support a component—or when CAD files, drawings, tooling, and engineering records have been lost—reverse engineering can recreate the engineering data needed to manufacture replacement parts and extend the life of critical equipment.

Why Obsolete Parts Need Reverse Engineering

Organizations often face situations where:

• The original manufacturer is no longer in business.
• Replacement parts are unavailable.
• CAD files and drawings have been lost.
• Legacy equipment remains operational and critical.
• Lead times for replacement equipment are too long.
• Modern equivalents are incompatible with existing systems.

Rather than replacing an entire machine, reverse engineering allows companies to reproduce the specific component that has become unavailable.

Yes. In fact, most reverse engineering projects begin with no drawings, CAD files, or engineering documentation at all.

Engineers can reverse engineer a part using the physical component itself, measurements, 3D scanning, inspection equipment, and engineering analysis to recreate the original design.

Typical Reverse Engineering Cost Ranges

Simple Part $500–$2,500

Mechanical Assembly $2,000–$15,000

Tool & Die Reverse Engineering $5,000–$50,000+

Point Cloud to CAD $1,000–$100,000+

Aircraft & Defense Projects Custom Quote

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Factors That Influence Cost

Part Complexity

A simple machined block with a few holes may require only a few hours of engineering effort, while a complex casting with freeform surfaces can require significantly more modeling time.

Part Size

Larger parts generally require:

• More scanning time
• More measurement data
• More CAD reconstruction effort

Yes. Reverse engineering is often the first step in creating a Digital Twin, especially when original CAD models, engineering drawings, or product data are unavailable.

A Digital Twin is a digital representation of a physical asset that accurately reflects its geometry, structure, and, in many cases, its operational behavior. Reverse engineering provides the engineering data needed to build that digital representation.

How Reverse Engineering Supports Digital Twin Creation

When an organization has a legacy asset with limited or missing documentation, engineers can:

1. Capture the physical asset using 3D scanning and measurement technologies.
2. Create accurate CAD models through reverse engineering.
3. Generate engineering documentation and metadata.
4. Integrate the resulting models into simulation, PLM, BIM, IoT, or asset management systems.
5. Establish a Digital Twin that can be updated throughout the asset's lifecycle.

• CATIA
• Siemens NX
• PTC Creo
• SolidWorks
• Autodesk Inventor

Yes. Manufacturing drawings can be created from a scanned part, but the process involves more than simply scanning the component.

A 3D scan captures the physical geometry of the part, while engineers use reverse engineering techniques to create an accurate CAD model and generate production-ready manufacturing drawings.

The final drawing package may include:

• Orthographic views
• Dimensions
• Tolerances
• GD&T
• Material specifications
• Surface finish requirements
• Notes and callouts
• Bill of Materials (BOM)

Yes. Aerospace and defense reverse engineering is a specialized engineering service used to recreate, modernize, and support legacy aircraft, military systems, ground support equipment, tooling, and mission-critical components when original engineering data is unavailable or obsolete.

Organizations throughout the aerospace and defense industries use reverse engineering to maintain operational readiness, extend service life, and create modern digital engineering assets for aging platforms.

• Reverse engineering specialists since 1988
• Millions of CAD models completed
• 100+ engineers and drafters
• CATIA, NX, Creo, SolidWorks, and Inventor experts
• Aerospace, defense, industrial, and government experience
• U.S.-based engineering team
• ITAR-capable projects
• Model-Based Definition (MBD) expertise
• Digital Twin and engineering modernization support

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.

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.

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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.

• 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.

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.
  

Yes with both the DeskTom and EasyTom CT scanners.  They both support metrology grade Computed Tomography (CT) inspection.  This provides nondestructive, 3D Scanning of Internal and External Geometries.  We use the Volume Graphics VGStudio Max high-end industrial CT software for the demanding of CT applications.

Yes. This is one of CT scanners’ major points – to see into objects. This is the best solution for nondestructive quality control.

• 4 to 400µm/voxel resolution
• Full inspection of large size samples
• Modular and micro-resolution capability
• 6 motion axis

For 3D scanning services our minimum order fee is $120.

Depending on the situation we can offer you dissecting your part for scanning purposes or use CT if applicable.

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.

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.

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.

We have a minimum order fee $150.

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 sales@cadcam.org

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.

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.

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.

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.

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

The Presidential Policy Directive 21 (PPD-21) is a Critical Infrastructure Protection and Resilience United States directive that aims to strengthen and secure the country’s critical infrastructure.The goal of this directive is to reduce vulnerabilities, identify and disrupt threats, minimize consequences and hasten response and recovery efforts related to critical infrastructure.

The directive defines resilience as the ability to prepare for and adapt to ever changing conditions, terrorists, and withstand and recover rapidly from disruptions. Resilience includes the ability to withstand and recover from deliberate attacks, accidents, or naturally occurring threats or incidents.

The Department of Homeland Security has identified 16 different infostructures:

1. Chemical Sector,
2. Commercial Facilities Sector,
3. Communications Sector,
4. Critical Manufacturing Sector,
5. Dams Sector,
6. Defense Industrial Base Sector,
7. Emergency Services Sector,
8. Energy Sector,
9. Financial Services Sector,
10. Food and Agriculture Sector,
11. Government Facilities Sector,
12. Healthcare and Public Health Sector,
13. Information Technology Sector,
14. Nuclear Reactors Materials and Waste Sector,
15. Transportation Systems Sector,
16. Water and Wastewater Systems Sector.

This is both Government and private sectors.

If you are in any of these industries, this directive is important to you for many reasons.  Do you know where your critical sections are? Are they well protected? Are there concerns for Hazmat, security clearance requirements, and other concerns?  Can you quickly rebuild what might be lost?

The important part of this means that critical infrastructure must be secure and able to withstand and rapidly recover from all hazards. Achieving this will require integration with the national preparedness system across prevention, protection, mitigation, response, and recovery.

Further details can be found at:  Government PPD-21

DHS – The National Infrastructure Protection Plan details:  The National Infrastructure Protection Plan

Industry specific plans:  2015 Industry specific PPD-21 plans

CAD / CAM Services provides PPD-21 for the following industries:  DHS – CAD / CAM Services

Depending upon when you catch us, yes, we can handle rush jobs. We often work over the holidays, Thanksgiving and even Christmas holidays. If you have a deadline – call us.

For years we have run three shifts of about 30 drafting folks per shift – allowing us to deliver work 3x faster, and seven days a week. Yes, we work 24/7, so you do not have to. The fun never stops here.

For 3D scanning, this is a different question. Because of the common setup work required, at best expect a 48-72 hour turn to be scanned. CAD or simulation services are in addition to that.

A Finite Element Analysis (FEA) is a form of non-destructive testing (NDT) that shows how your part reacts to real-world loading events. A common example is running an FEA on a support bracket. The FEA will give results showing how much the bracket deflects, how much reactive force is seen, and the kind of internal stresses the bracket experiences.

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FEA results will change dramatically based on the position and angle of the load, how much force is applied, the material properties of the part, and the design of the part itself.

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An FEA is used to optimize a part before manufacturing begins. It allows you to find weak points within your part or assembly, and it will predict a failure before you physically make anything. This gives you an opportunity to fine-tune each part to optimize its size, strength, and cost before you start producing it.

The more information we have, the more accurate the simulation results will be. It also depends on what type of simulation you want to run. For a simple FEA, we can run an accurate simulation with just a 3D CAD model and loading/force/pressure information that you want to simulate.

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Don’t have a 3D model? Not a problem, our team can make one for you from scratch, and then run an FEA on it.

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For a more detailed answer, a well-run FEA will need:

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• Material properties: What material is the part made out of? We can run different FEAs with different materials to help you pick the right one.

• Loading conditions: The size, location, and type of load you want to simulate.

• Bonding condition: How is the part held in place? Is it bolted, welded, or just sitting on a tabletop?

• A 3D model

• For other simulations: Please provide us with all thermal, dynamic, aero, and/or fluid flow information. Feel free to call us and we’ll walk you through what we need.