Portable CMMs and software make reverse engineering useful for modifications, new designs, and duplicating parts without drawings. If you can measure an object, you can reverse engineer it. The key is measuring with sufficient accuracy to capture the degree of detail necessary for a faithful reproduction. The concept behind reverse engineering (RE) is simple. First, measure the object or part. Then transcribe dimensions into a digital or CAD-compatible format as an image of dots, streaming lines, or wire frames. The image can be enhanced for end use by engineering programs that deal with surfacing, stress analysis, human factors, ergonomics, plant layout, or product flow. Several examples of reverse engineering show its usefulness. For instance, engineers in a steel mill needed to replace an aging 7,500-hp motor. The problem: The new motor would not fit on the old mount. Reverse engineering let engineers design an adapter so the old mount could accept the new motor. RE also recreates drawings for old parts. For example, a blade on the impeller of an air compressor broke off after years of service. But the compressor manufacturer asked for eight months to make a new one. Plant engineers decided to reverse engineer a new one from the original, and measured the dimensions to digitally capture blade locations. Shaft and bearing dimensions were also recorded. This data was loaded into a CAM program to generate a machining plan. The new impeller was milled from an aluminum blank with the toughness and corrosion resistance at least equal to the original. From start to finish, the project took only three weeks.
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