eBook Drive Product Innovation with Reverse Engineering...2020/05/15 · Inspiring Great Design...

eBook

Drive Product Innovation with Reverse EngineeringExtract New Value from Old Products

SCAN IT 3DMail: [email protected] Tel: +49 1512 69 81 044 www.scanit3d.ch

23D SYSTEMS | EBOOK | DRIVE PRODUCT INNOVATION WITH REVERSE ENGINEERING | MAY 2020

Contents03 DefiningReverseEngineering

04 InspiringGreatDesign

05 AddingValuetotheProductLifecycle

06 IdentifyingCommonProductDevelopmentChallenges• MissingCADFiles

• Archaic,AdHocReverse-EngineeringTechniques

• InabilitytoExtractDesignIntent

• InadequateSoftware

• AdoptionBarriers

10 ImplementingModernReverseEngineering• Top5KeyFeaturesofDedicatedReverse-EngineeringSoftware

• ProvenReverse-EngineeringSolution

• SpeedComparison

• Top5Reverse-EngineeringImplementationChecklist

• FreeTrialandConsultation


Defining Reverse EngineeringEverytimeyoucapturephysicalrealitytouseaspartofyourdigitaldesignprocess,youareengaginginreverseengineering.

Whetheryoucallitreverseengineeringorsomethingelse,youarealmostcertainlymeasuringphysicalpartsandusingthosedimensionstoinformmultipleaspectsofyourproductdesigns.Andyouareprobablydoingthismultipletimesthroughouteachproductlifecycle.

Amodernapproachtoreverseengineering—backedbythelatestmeasurementtechnologyandsoftware—candrivevaluethroughoutyourbusiness.

• RebuildCADdataforlegacypartsandtooling.

• Designnewcustomproductsthatfitin,on,oraroundexistingones.

• Documentchangesmadepost-prototypeormanufacture.

• Recreatenon-existentorlostCADdataforpartsandmolds.

• ConvertphysicalpartsintoCADfornewproductdesigns.

Asapractice,reverseengineeringisasoldasengineeringitself.Thankstocontinuingadvancesinhardwareandsoftwaretechnology,reverseengineeringisnowsofast,accurate,andeffectivethatithasbecomeanintegralpartofmodernproductdesign.

“Theshiftfrom2Dto3Danalyseshasmadeatremendousdifference.Ithasenabledustoexpandouranalysesandgeneratereplicableresults.”

Dr.RobertZ.Selden,Jr.,CenterforRegionalHeritageResearchAssociate,StephenF.AustinStateUniversity,Nacogdoches,Texas,USA


Inspiring Great DesignEverygreatdesignisinspiredbyanother.

Pioneeringmanufacturersaredeployingmodernreverseengineeringtodrivebusinessvaluethroughoutthedesign,manufacture,andmaintenanceoftheirproducts.

“We’vealwaysbuiltcoolstuff.Butnow,withtheaddedtechnology,we’rebuildingevencoolerstuff—inalotlesstime.”

DaveKindig,Owner,Kindig-ItDesign,SaltLakeCity,Utah,USA

Additive ManufacturingReapplydesignintenttogenerativemeshresultsfromtopologically-optimizedpartsandgetfeature-basedresultsthatyoucaneditandusewithinCAD.

Supply Chain OptimizationReduceleadtimesandcentralizeyourknowledgeandmanufacturingcapabilitybycreatingadigitalinventoryforcriticalpartswithhighwearorpartsthatoftenfail.

Sheet Metal StampingScanstampingdiesthathavebeenmodifiedpostproductionsothatyoucanmodifytheoriginalCADdesignstoreflectreal,as-builtconditions.

Product DesignSignificantlyreducetimetomarketbyusingreverseengineeringtocombineoff-the-shelfpartsandassemblieswithcustom-designedparts.

CastingQuicklycreatemanufacturabledigitalmodelsforbrokencastingswithnodesignplanstorebuildandremanufacturecriticalcomponentsusing3Dscanningandscan-baseddesign.

Redesign and CustomizationStartwithanexistingpart—likeavehicle,vehiclecomponent,orproductthatpreciselyfitsthehumanbody—anduseitasareferencetocreatebrandneworcustom-fitparts.

PrototypingCreatemanufacturabledesignsfasterbydigitizing hand-builtprototypesandprototypestypically fabricatedwithfoam,cardboard,ormodelingclay.

Remanufacturing and MaintenanceProtectexpensiveheavyequipmentfromemergenciesandkeepitrunningefficientlybyusing3Dscandatatocreatespareandreplacementparts.


Adding Value to the Product LifecycleReverseengineeringaddsvalueateverystepoftheproductlifecycle.

Tocreateandsustainlong-termvalue,manufacturersknowthattheyneedtotakeaholisticviewoftheentireproductlifecycle.Thebest-performingcompanieshavemasteredtheabilitytomoveseamlesslyfromdigital,tophysical,andbacktodigitalthroughouttheproductlifecycleusingtechnologylike3Dscanning,reverse-engineeringsoftware,digitalmetrologysoftware,and3Dprinting.

CONCEPT• Startfromexistingproducts.

• Benchmarkyourcompetitors.

DESIGN

• Ensuredesignswillinterfacewithexistingproducts.

• Capturechanges made tophysicalprototypes.

MANUFACTURE• Speeduptoolingdevelopment.

• Compensatedesignfilestoreflectas-manufacturedstate.

SUPPORT AND MAINTAIN• Manufacturereplacementparts.

• Createtoolingdigitalarchives.

DISPOSE AND REUSE• Leverageintellectualpropertylockedupinphysicalparts.

• Documentas-manufacturedpartsinCAD.

“The3DCADdataprovidesabaselineforwearinspection,rework,andredesign.Withoutit,changesandrepaircanbeanightmare.”

DaveChrisman,ProcessEngineer,B&JSpecialty,Inc.,Wawaka,Indiana,USA

CONCEPT

DESIGN

MANUFACTURESUPPORT AND MAINTAIN

DISPOSE AND REUSE


Identifying Common Product Development ChallengesDesignersandengineersoftenencounterproductdevelopmentchallenges.

“That’sthegreatthingaboutthiskindoftechnology.Partsarenolongerlosttotime.We’rereadytogoforanotherhundredyears.”

JayLeno,Owner,JayLeno’sGarage,Burbank,California,USA

Adoptionbarriers

Inabilitytoextractdesignintent

Inadequatesoftware

Archaic,adhocreverse-engineeringtechniques

MissingCADfiles

Readontolearnmoreaboutthesechallengesandhowtoovercomethem.


Missing CAD Files

Veryrarelydoesdesignworkoccurinavacuum.Newproductsusuallyrelyonexistingcomponents,interfacewithotherproducts,orareinspiredbyexistingdesigns.

Theideathatyoucandesignamanufacturablepartwithablankscreenandcreativityissomewhatofamyth.Youmustdesignallproductswithincertainconstraints,andmanyoftheseconstraintsaredimensional.

Withaworldquiteliterallyfullofobjectstoleverage,itismuchmoreefficienttostartwithexistingproductsthatyouknowalreadyperformwell.

However,90percentormoreproductsdonothaveexistingCADfiles.WhenCADdesignfilesactuallydoexist,theymaybe2Ddrawingsorplansorout-of-date3Dfilesthatdonotreflecttheas-manufacturedproduct.Designersenduphavingtoreinventthewheelandspendsignificanttimeandeffortrecreatingthedesignsfromscratch.

ReverseengineeringenablesyoutorecreateCADfilesforexistingproducts.

“Weneededa3Dmodelofthe1960s-eraBirdMark7ventilatoras-built,butthemoldsanddrawingshadbeenlost.Soweusednon-destructiveCTscansandreverse-engineeringsoftwaretointerpretthosescansintonativeCADfilesinonly24hours.”

DavidP.Fergenson,Ph.D.,CEO,LivermoreInstruments,Inc.,Oakland,California,USA


Archaic, Ad Hoc Reverse-Engineering Techniques

Teamsoftenstrugglewitharchaic,adhocapproachestoreverseengineering.Althoughyoumaynotthinkofitassuch,theuseofevenlimitedmeasurementsinnewproductdesignisaformofreverseengineering.

Measuringpartswithbasichandtools—includingmicrometers,calipers,andevenrulers—foruseinCADmodelstoinformdesignisslow,tedious,error-prone,anddifficulttoverifyforaccuracy.

Coordinate-measuringmachines(CMMs)orportablearmscanmeasuremoreaccuratelyin3Dspacethanhandtools.However,notonlyaretheseoptions time-consuming,theyalsoonlyprovideafewdimensions,don’tprovidethefullpictureorcapturethefullshapeforindefinitestorageandreference,andpotentiallymissimportantdetails.Resolutionmatters.

With3Dscanningandscan-basedreverseengineering,yougetfulldatacapturefast—ataspeedandresolutionthat’simpossiblewithsimplermeasurementtools.Forexample,3Dscanningisatleast2,500timesfasterthanprobing.

“Theentireprojecttookus50hoursinsteadof500,allowingustoachievesuccessinonly10%ofthetimeitwouldhavetakenuscomparedtousingconventionalmeans.”

BobbyMachinski,Owner,MACH-T3Engineering,Campbell,California,USA


Inability to Extract Design Intent

Thereisabigdifferencebetweenmanufacturingamodelandmanufacturingagood,useablemodel.Whenyouredesignanexistingpart,youneedtoolsthatenableyoutomakethesameorsimilarcompromisesanddesign-intentdecisionsintheredesignprocessastheoriginaldesigner.Justcapturingitsshapeorcomponentsdoesn’treallyhelpsolverealproblems,withquality.

Everymechanicalpartcontainsdesignintent—liketherevolvingaxisofawheelorgear,aspecificdimensionofafeature,ortheconstraintthataseriesofholesshouldbeofthesameradiusanddepth—hiddenwithinscannedparts.Extractingthedesignintentduringthe3Dscan-to-CADconversionprocessenablesyoutoeditthatdata,useitdirectlyfornewdesignandmanufacture,andgreatlyincreasesthevalueofthereverse-engineeringprocess.

Themeasureofsuccessforreverseengineeringisanaccurate,useablepartthatdeliverssignificantlymorevaluedownstream.Morethan90percentofscan-basedreverseengineeringfocusesoncreatingaCADmodelwithahistory-basedfeaturetreeandeditabledimensionsandconstraintsthatyoucantransfer,intact,tomainstreamCADapplications.

Inadequate Software

Evenifyouhaveahigh-quality3DscannerandalreadyuseCADsoftwarefordesignthatcanimportSTLfiles,youmayfindthatyoustruggletogetaccurate3Dmodelsorspendtoomuchtimeandefforttocreatetheright3Dmodel.

MostCADsoftwareprogramscannothandle3Dscansof evenmoderately-sizedmeasureddatasets,andarethereforeslow,cumbersome,andinefficienttouseforreal-world reverse-engineeringtasksonaregularbasis—evenwithoptionalreverse-engineeringmodules.

Forrealengineeringchallengeswherequalityandaccuracymatter,youneeddedicated,scan-basedsoftware.

Adoption Barriers

Barrierstoadoptingreverse-engineeringmethodscan leadtomissedopportunitiesandbenefits.

Manyteamsavoidreverseengineeringbecausetheydonothavetherighttoolstodoitquickly,accurately,andcost-effectively.But,withtheright3Dscannerandreverse-engineeringsoftware,youcantakeanyphysicalpartandbringitintoyourdigitaldesignenvironment,speedyourproductdevelopmenttime,andleverageexistingpartsinsteadofdesigningfromscratch.


Implementing Modern Reverse EngineeringFortunately,thereisabetterway.ReplacingyourexistingCADsoftwarewithdedicatedreverse-engineeringsoftwarefor3Dscan-baseddesignhasmanybenefits.

Amodernreverse-engineeringapproachaccuratelycapturesthecompletegeometryofvirtuallyanythingthatyoucanscanandyieldseditable,manufacturable3DCADmodelsthatmeetspecificengineeringandmanufacturabilityrequirements.Inaddition,thisprocessisfaster,lessexpensive,andeasierthaneverbefore.

Someofthemanybenefitsofmodernreverseengineeringinclude:

• Broadeningyourdesigncapabilities

• EnhancingyourCADenvironment

• Acceleratingtimetomarket

• Leveragingexistingassets

• Reducingcosts

• Doingtheimpossible

“Usinga3Dlaserscannerandsoftware,wecanreverseengineerequipmentinafractionofthetimeittakestomanuallyaccomplishthistask.”

BobbyMachinski,Owner,MACH-T3Engineering,Campbell,California,USA


Top 5 Key Features of Dedicated Reverse-Engineering Software

Whenshoppingfordedicatedreverse-engineeringsoftware, lookforfivekeyfeatures.

“Theaccuracyanalyzerfeaturecalculatesthespatialdistancebetweenthemeshandthegeneratedsurfaceandthenassignsacolortothedistance.Itshowsyouhowaccurateyourmodeliscomparedtothemeshthatisbasedontheactualscandata.”

ChristianStark,Engineer,Bellingham,Washington,USA

Real-time accuracy analysis helps ensure models are correct and true. WithmainstreamCADprograms,youoftenhavetostopmodelingandexporttheCADfiletoanotherapplicationtocheckdeviation.Real-timefeedbackistheonlywaytoanalyzetheaccuracyofyourCADmodelontheflyduringeverystepofthereverse-engineeringprocess.

Automated sketching increases accuracy by removing the need to estimate.WithmanyCADprograms,youtypicallyhavetohand-selectpointstoformsketchesor,worse,relyonvisualapproximationstoguesswherethesketchesshouldgo.Youshouldbeabletofitsketchlines,arcs,andcurvesontoscannedpartsmoreaccuratelybybestfittingtotensofthousandsofpointsonamodelautomatically.

Automated feature creation speeds up modeling.CADmodelshavehundredsorthousandsoffeaturesdescribingeveryaspectofagivenpart.Savingjustoneminutewhenmodelingeachfeaturecanadduptohundredsorthousandsofminutes.Commonfeaturemodelingoperationsthatyoushouldbeabletoperformautomaticallyinsecondsinclude2Dand3Dsketch,revolve,extrude,fillet,shell/thicken,andpipe.

Fitted NURBS surfacing makes it easy to capture complex, freeform geometry.Somepartregionssuchasrough,unmachinedcastingportionsdonotrequiredesignintentextraction.Whereappropriate,youshouldbeabletocaptureas-builtNURBSgeometryautomaticallytoblendautomaticsurfaceswithsolid-modeledfeaturesseamlessly.

Seamless data exchange to multiple CAD applications for a native, editable CAD file. CADmodelscreatedinstandalonesoftwaresometimeshavecompatibilityissueswithCADsoftware.YoushouldbeabletoconnectdirectlytomostCADsoftwareprogramsandtransfereachfeatureautomatically,whichyieldsaparametricmodelwithcompletemodelinghistoryinyourCADsoftwareasthoughyoucreateditthereoriginally.


Proven Reverse-Engineering Solution

Onesoftwareprogrambringsthisalltogether:Geomagic®DesignX™by3DSystems.

GeomagicDesignXreverse-engineeringsoftwaremakesiteasytoextractnewvaluefromexistingproductsbycreatingCADmodelsfrom3Dscansfaster,moreaccurately,andmorereliablythananyotherreverse-engineeringmethod.ItconnectsdirectlytoyourexistingCADenvironmentandcreatesnativefilesthatyoucanusethesamewayasanyothermodel—exceptthatitaccuratelyrepresentsascannedobject.

Geomagic Design X checks all the boxes:

3–10XfastertimetoCAD Real-timefeedbackwithpatentedaccuracyanalyzer

Handleslargescandatasetsfasterthananyothersoftware

SeamlesslivedatatransfertomostCADsoftware

Mesheditingandpoint-cloudprocessing

OnlysoftwarethatcombinesscanprocessingandCAD

Automatic,guidedsolid-modelextraction

Easytolearnanduse

Accuratesurfacefittingtoorganic3Dscans

Regularupdates

Automatedfeaturecreationandsketching

WWlocalsales,training,andsupport

Provenandtrustedsince1998 Vastnetworkofscannerpartnerships

14,500+licensesinuse

“GeomagicDesignXisthebestreverse-engineeringsoftware,providingagreatfeaturebalanceandeasilyhandlinghugepointclouds.Itsflexiblemodelingmethodsmakeittheidealtoolforawiderangeofchallenges.”

NorimichiAbe,GroupLeaderofGeneralControlGroupforCADMachineProcessing,AsanoCo.,Ltd.,Isesaki,Gunma,Japan


Speed Comparison

Let’slookatthefacts.3DSystemsregularlyreceivesfeedbackfromitscustomersaboutmainstreamCADsoftwarescan-to-CADworkflows.Customerfeedbackindicatesthatonverysimplemodelslikewhatyoumayseeinasoftwaredemo,ittakesanexperienceduserthreetoeighttimeslongertocreateanaccurate,high-qualityCADmodelfroma3DscanusingmainstreamCADsoftwarecomparedtoGeomagicDesignX.

Asmodelcomplexityandfeaturecountincrease,reverse-engineeringtimeincreasesatanevenfasterrate.Thiscanadduptohours’orevendays’worthofadditionaltimespentonreverseengineering.ItisnowonderthatthosewhoregularlyreverseengineerobjectsrelyonGeomagicDesignXsoftwaretodoit.

“We’resavinghundredsofmanhours/yearusinga3DscannerandGeomagicDesignXtoscananddesigndirectlyfromthescandata—moreprecisely,withhighercustomersatisfaction.Gettingthefitrightthefirsttimeresultedina100%ROIinthefirstyear.”

AntonioCapristo,Owner,CapristoExhaustSystemsGmbH,Sundern,Germany

• 3XfasterthanmainstreamCAD(ignoringaccuracy)

• 8XfasterthanmainstreamCAD(maintainingaccuracy)

REVE

RSE-

ENG

INEE

RIN

G T

IME

MODEL COMPLEXITY (NUMBER OF FEATURES)

MainstreamCAD(ignoringaccuracy)

MainstreamCAD(maintainingaccuracy)

UP TO 10X FASTERTIME TO CAD


Top 5 Reverse-Engineering Implementation Checklist“WithabackgroundinCAD,GeomagicDesignXisratherintuitive.Ifounditveryeasytolearnanditdoeseverything Ineedittodo.”

JohnAnastos,AerospaceEngineer,AdvancedVehicleResearch,Greenville,SouthCarolina,USA

Break down the barriers between measurement and design. Directlyinvolvedesignersinthescanningandscan-basedCADmodelingprocessbyhavingproductdevelopmentandengineeringdepartmentsoperatescannersdirectlyorworkcloselywithinspection/qualitydepartmentsthatoperatescanners.

Identify multiple applications for 3D scanning and reverse engineering.Whereverpossible,leveragereverse-engineeringexpertiseandbuildstakeholdersupportacrossyourorganizationtomaximizeyourreturnoninvestment(ROI)andbusinessimpact.

Select the right 3D scanner.Carefullyselectthe3Dscannerthatcoversmost,ifnotall,ofyourmeasurementneedsandworkwithtrustedoutsideservicebureausfortherest.

Don’t use measurement software for design. Mostbundledscannersoftwarefocusesontakinggreatscans—notonapplyingdesignprinciplestoextracttheunderlyingfunctionalintentofapart.Instead,usededicatedreverse-engineeringsoftwarelikeGeomagicDesignXfordesign.

Don’t use design software for measurement. AlthoughitistemptingtouseyourexistingCADsoftwaretocreateCADmodelsfrom3Dscans,itisslow,cumbersome,andinefficientforregularuseinreverseengineering.Specializedscan-to-CADsoftwarelikeGeomagicDesignXandinspectionsoftwarelikeGeomagicControlX™aremust-havesforanyoneseriousaboutreverseengineering.

Checkoutfivekeytipstoadoptreverseengineeringinsideyourorganizationsuccessfully.

TryGeomagicDesignXforyourselfwitha15-dayfreetrial.

Free Trial and Consultation

Request Free Trial

3dsystems.com

Wherecouldyouenvisiondeployingmodernreverseengineeringinyourcompany?

3DSystemsisheretohelp.Webelieveinacollaborative,customer-centricapproachwherewebeginbyunderstandingyourpriorities,challenges,needs,anddesiredoutcomes.

Contact our reverse-engineering experts to discuss your specific applications.

SCAN IT 3DMail: [email protected]. +49 1512 69 81 044www.scanit3d.ch

https://www.3dsystems.com/software/geomagic-design-x?utm_source=Pardot&utm_medium=Email&utm_campaign=7012T000001dIEZ&utm_content=DXeBookFreeTrial#freeTrial

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eBook Drive Product Innovation with Reverse Engineering...2020/05/15 · Inspiring Great Design...

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