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