Reverse Engineering Services

Digitize your products and parts for various applications through reverse engineering in Toronto.

Reverse engineering typically refers to the construction of 3D CAD models based on the use of various 3D digitizing technologies. The process of reverse engineering the automotive parts included high-precision 3D scanning, data processing, and 3D modeling to provide the ‘as-built’ models. 

3D scanning captures important geometry from a part or tool where a CAD model has been lost or does not exist. A wide range of CAD data formats can be created once the processing of the 3D scans is complete. The data can be used to develop tooling, including molds, dies, and fixtures, as well as a basis for quality inspection.

What are the Processes of Reverse Engineering?

Automotive Part 3D scanning

Precision 3D Scanning

Precision 3D measurement is the starting point of reverse engineering. In this step, our experts used a Zeiss structured-light 3D scanner to capture the "as-built" condition of the part. The part was set on an integrated turn table while the blue-light scanner emitted a visible light source, and the camera system recorded the observed pattern and its changes on the object. The patterns were recorded as “point clouds"— a collection of millions of precise X, Y, and Z coordinates, as 3D data points. 

3D CAD Modeling

Then the scans were processed into complete 3D models. Based on the high-quality 3D ‘point cloud’ data, each scan was aligned together to form the contour of the object, as a mesh or STL. The mesh was then cleaned, repaired, and refined. The updated mesh was imported into CAD software to construct a complete 3D model by adding or extracting elements, refining and smoothing out the surface on the part.

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Why Should You Apply Reverse Engineering to Your Projects?


  • Recreate non-existent or lost CAD for parts and molds
  • Rebuild CAD for legacy parts, tools, and molds 
  • Create new designs in reverse engineering software based on physical parts 
  • Construct physical parts based on 3D CAD model using 3D Printing


Capturing complex, organic geometry for critical parts and assemblies 

Modern designs combine various types of materials into complex, organic shapes. Although traditional 3D measurement, such as with a CMM, is very accurate, it only provides a limited level of detail. Fortunately, structured light scanners project light on the part and quickly collect millions of precision 3D points within seconds. The tiniest details on complex surfaces can be captured almost immediately with an accuracy of up to 10 microns.

Fast and accurate model creation

Reverse engineering offers designers, engineers, and quality professionals the capability to re-create 3D models based on physical parts or tooling. When you need to refine your early product designs or existing parts, our experts can make quick iterative changes to the 3D CAD data in our highly specialized 3D software, including shaping, surfacing, and creating high-quality symmetric 3D models.

Enabling tests & simulations in the digital environment

After 3D reverse engineering, precisely captured parts and assemblies can be analyzed, modified, and used for other optimization processes. With the 3D data, engineers can conduct FEA (Finite Element Analysis), CFD (Computational Fluid Dynamics), and other analytical simulations in a digital environment.

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About Applied Precision 3D

With 20+ years of professional 3D experience, Applied Precision 3D is your expert resource for 3D services in the Greater Toronto Area.