Reverse Engineering Legacy Parts Utilizing 3D Scanning & SolidWorks Modeling
Imagine holding a vintage car or airplane part with no blueprints, or a custom prosthetic
needing modification—all without original CAD files. Enter 3D scanning and SolidWorks
modeling: a dynamic duo that transforms tangible objects into data that you can either
immediately duplicate, or put added effort into creating editable, parametric digital copies. This
post will give you an idea of what that process looks like, exploring how these tools aid in
engineering, part recreation, and innovation. Whether you’re restoring antiques or prototyping
upgrades, we’re mastering this workflow, to shave weeks off development time, and utilize
rapid iteration to its fullest. By the end, you’ll have an overview of one of AZ3DPrint’s most
utilized services.
The Caveat
Every customer has different needs and expectations. The workflow to meet the needs varies
from part to part, shape to shape. At its core, scanning to 3D model is the art of deconstructing
a part to reveal its design intent, fitment, and functionality, often to replicate, improve, or
analyze it. In manufacturing, it accelerates time-to-market for legacy parts; in R&D, it fuels
competitive analysis. With supply chain disruptions and sustainability pushes, reverse
engineering has surged in relevance. The global 3D scanning market, projected to hit $10 billion
by 2028, underscores this trend, driven by purpose driven hardware like our Artec Leo, Space
Spider & Keyence VL Series Scanners.
But why pair 3D scanning with SolidWorks? Scanning captures geometry non-destructively,
while SolidWorks—a parametric CAD powerhouse from Dassault Systèmes—turns raw data into
BREP surfaces, or gives us the data necessary to create editable parametric models. Unlike
mesh-based tools, SolidWorks excels at feature-based design, allowing edits that propagate
changes across assemblies. This synergy is ideal for reverse engineering, where accuracy meets
adaptability.
Basics of 3D Scanning
3D scanning is a massive departure from using calipers, height gages, laying string lines and
making cardboard cutouts; converting physical objects into point clouds or meshes via laser, or
structured light. Picture zapping a laser across a surface to measure points in space millions of
times per second—voilà, a 3D point cloud emerges.
Types of Scanners We Use
Handheld Scanners (e.g., Artec Leo or Artec Space Spider): Portable powerhouses for parts large
and small, from tractor trailer truck to 1” cube. They shine in dynamic environments, capturing
up to 35 million points per second (1 million for Space Spider) with sub-millimeter accuracy
(0.004” or 0.1mm for LEO and 0.002” or 0.05mm for Space Spider). Ideal for on-site scanning of
components.
Desktop Scanners (e.g., Keyence VL 770): Stationary setup for precision work on objects roughly
the size of a shoebox or smaller. Offers the ability to do either a Low Magnification scan, which
captures a wider field of view, or a High Magnification scan which is slower, but can capture
ultra-fine resolution (features down to 0.004” or 0.1mm). The VL 770 offers a measurement
accuracy of ±10 μm, 0.00039” or 0.01mm.
What Happens to the Part
Preparation is key: Clean your object; any leftover glue, tape or other debris on the part with
show up in the scan and it’s easier to fix it now, than in the data later most times. Some
surfaces may require the application a matte spray in order for the scanners to pick up good
coordinates in the scan, and the use of markers (sticky dots, magnets or pen marks) for
alignment in multi-scan setups. Scanning time varies—minutes for simple shapes, hours for
larger or more complex shapes. The part data is created and turned into point cloud data that is
usually converted to .STL format and exported. The exported data can, at that time, usually be
taken directly to the 3D printing software, if the part is to be 3D printed as a direct copy; but,
usually the data will then be taken from the scanning software directly into Solidworks, to be
either converted to a surface model, or a parametric solid.
The Benefits of Scanning to Model
Beyond speed, 3D scanning ensures fidelity. Traditional measurement tools like calipers and
height gages make measuring contoured surfaces and complex shapes difficult and extremely
time-consuming; scans capture them holistically. It also enables non-contact inspection,
preserving fragile artifacts, textures and, in some cases, color variation. In aerospace, a lot of
legacy parts have no CAD data behind the parts, and old prints don’t always reflect the true
form of those parts; scanning is a great way to digitize obsolete parts, cutting redesign costs by
70%. For the average customer, it’s a game-changer: Scan a broken drone wing, repair the scan
in SolidWorks, and 3D print a replacement.
Challenges in 3D scanning: noise from reflections or occlusions. Deep slots, sharp edges or
holes can be challenging to capture with 3D scanners. With software like Artec Studio:
Decimate meshes to reduce file sizes (from gigabytes to megabytes), fill holes, and smooth
artifacts. Pro tip: tape over tall fins or difficult to capture holes, and add them in cleanly in
Solidworks later, if you can measure the hole or slot locations and sizes the old-fashioned way.
Solidworks
SolidWorks isn’t just software; it’s a parametric playground where sketches evolve into parts,
assemblies with mates, simulations, and renders via add-ins like Geomagic for Solidworks.
Why SolidWorks for reverse engineering? Its hybrid modeling blends meshes with NURBS
surfaces, bridging organic scans and engineered solids. Features like the Geomagic for
Solidworks plug-in can bypass SolidWorks’ native limitations on dense scans.
Getting started: Open a new document in the units you’d like to work in. Import your STL via
the Geomagic plug-in interface, and SolidWorks renders it as a graphics body—non-parametric
but referenceable. From here, the real engineering begins.
Step-by-Step Workflow: From Scan to SolidWorks
Harnessing this power requires a methodical approach. Here’s a battle-tested pipeline, distilled
from industry guides and years of experience.
Step 1: Scan and Pre-Process (Prep Phase)
Part size and Customer needs will decide which scanner to use, and sometimes scan data is
captured with multiple scanners to patch finer features on to larger scanned bodies. Multiple
passes ensure overlap (60-80%) for stitching.
In dedicated software (e.g., Artec Studio 19 Proffessional), align scans, reduce noise, and
generate a watertight mesh. Filling holes, smoothing surfaces, and bridging gaps is best done
here. Try to balance getting enough detail without bloating file sizes.
Step 2: Import and Analyze in SolidWorks
Launch SolidWorks with Geomagic plug-in, import the STL. Identify datums, flat faces or axes,
for alignment. Position the mesh in such a way as to make modelling easier, aligning planes and
reference points to the Universal Coordinate System of what will be your Solidworks part. Use
Geomagic tools to simplify and/or heal any remaining artifacts that may be found before
convert to a mesh data to BREP surface model. Or, utilize the Geomagic tools to pull feature
data, like profiles and silhouettes from created planes, to aid in the creation of Sketches for a
Parametric Solid.
Analyze: Measure deviations with the 3D Compare tool against reference models. If the decision
was made, to create an initial model from the mesh data, before the Parametric Model was
created, then the capability to utilize Solidworks 3D Compare tool is available, as an added way
to check the work output to the original scan data.
### Step 3: Surface Extraction and Feature Recognition
This is where artistry meets engineering. Use the Surface Wizard to auto-generate NURBS from
mesh sections. For complex curves:
– **Slice and Sketch**: Cut planes through the mesh, trace profiles with splines. Extrude or
revolve to solids.
– **Fit Curves and Surfaces**: Tools like Curve Through XYZ Points fit scans to equations. Loft
between sketches for organic shapes.
– **Hybrid Modeling**: Reference the mesh as a background, building parametric features atop
it. For example, detect holes via edge detection and pattern them.
Break it down: Model primitives first (cylinders, planes), then blend with fillets. Plugins like
Power Surfacing accelerate this for freeform parts.
### Step 4: Assembly and Validation
Assemble components, mating via coincident relations to the original scan. Run interference
checks and simulations (e.g., stress analysis) to validate.
Export iterations for 3D printing or CNC—STL for additive, STEP for subtractive. Iterate: Rescan if
tolerances slip.
A real-world example? Reverse-engineering a vintage gearbox: Scan the housing, model gears
parametrically in SolidWorks, simulate loads. Result? A lighter, stronger redesign printed in
titanium.
Time estimate: 1-10 hours per part, depending on complexity. With practice, it’s a very
repeatable process.
Navigating Challenges: Pitfalls and Pro Tips for Success
No workflow is flawless. Dense meshes can crash SolidWorks while utilizing some of the more
demanding tools. Decimate aggressively—aim for under 500k facets. Organic shapes defy
parametric modeling. Be creative, and try to simplify your modeling style in ways that will
enable easier changes to the model later. Make all of your sketches fully defined. The Anchor
button is your enemy. Keep in mind the design intent of each part (they’re all different) when
modelling, to make the part easily editable later. Embrace hybrid: Keep meshes for
visualization, or BREP solids for shapes too challenging to do a parametric solid of, as long as the
customer requirement will allow it. BREP solids will likely not be good for a part that goes on to
CNC machining, but it’s perfectly usable for a part that will be additively manufactured.
Accuracy dips from vibrations in a part while scanning. Thin parts can twist into a different
shape when turned from one side to the other between scans. Use anti-vibration mats, bracing,
weights and clamps, to name a few, to aid it getting good scan data in. Shiny parts, or parts that
absorb the reflected scanner light, may need scanning spray to get the best scan data possible.
Best practices:
Document Everything: Tag scans with metadata (scale, orientation).
Tolerancing: Cross-reference known dimensions with for critical dims with precision scan data,
like the Keyence provides—scans are guides, not gospel, especially on larger parts, and parts
that deform between scans.
Sustainability Angle: Digitize your workflow, prototype assemblies for virtual testing pre-
production, reducing physical prototypes by 50%.
The Future: AI, AR, and Beyond in Reverse Engineering
As we lean forward, 3D scanning evolves with AR overlays for real-time modeling—scan a part,
SolidWorks AR visualizes edits on-site. AI will automate 80% of surfacing, per Hexagon’s 2025
forecasts. Quantum computing? It could simulate scan-derived materials at atomic scales. The
time is coming, when AI will be able to understand 3D models, in 3 Dimensions. That is still
years away from implementation in small manufacturing environments; but, it’s something to
look forward to, and it will be a game changer.
Reverse engineering isn’t theft. It is a worthwhile skill that can be used with good ethics; much
the same way a locksmith does not make a thief. With 3D scanning and SolidWorks, you’re not
just copying; you’re elevating. Grab the scanner. Let’s fire up SolidWorks, and re-engineer the
obsolete, nothing is impossible.
