Best software for reverse engineering reviewed by Artec 3D

Much can be said about capturing data for reverse engineering and how it’s done. For the purpose of this article, we will focus on the leading methods utilized today: 3D scanning, photogrammetry, CMM machines, and CT scanning. Each of these technologies has been chosen based on the industry or application it is primarily used in. We will also present any time and budget constraints that may prove to be a valuable consideration.

When it comes to reverse engineering a finished product or part, 3D scanning could be your best choice – it’s the quickest and easiest way to turn a physical object into a CAD model. Since a 3D scanner does not directly generate CAD models (it outputs point clouds or mesh data) you’ll need to utilize modeling tools for the next stage in this process: a workflow known as Scan-to-CAD, a semi-automated process during which professional software converts 3D data into an editable and design-ready CAD file.

The precise surface measurements provided by a 3D scanner are vital in this process. In fact, 3D scan data helps you leverage knowledge acquired from the real-world object, and digitally represent it most accurately. Data captured with the help of professional 3D scanners then takes the form of a usable 3D model, which renders the most thorough geometry of an object or a scene.

While CT scanners and CMM machines are often expensive, difficult to move around, and time-consuming in terms of training, 3D scanners are quite the opposite: reverse engineering benefits a lot from this speed, versatility, and ease of use.

There are various methods in 3D scanning technology used for capturing point clouds, with optical-based 3D scanning being by far the most popular. Optical-based 3D scanning is a non-destructive process that digitally captures and replicates an object projecting structured light and laser beams onto it.

The scanning software tools available today are diverse: from smartphone apps to smart 3D imaging programs that vary greatly according to operating systems, ease of use, and price. In any case, one of the hallmarks of well-developed software is that it should not take a long time for a user to get the hang of it. Ultimately, what matters most is that all the work you put into capturing data is translated into results with great accuracy, high resolution, and excellent quality.

Metrology-grade photogrammetry is another measuring technique that combines photos from different angles to form a 3D point cloud. A metrology-grade photogrammetry kit should consist of targets (adhesive or magnetic), scale bars, reference crosses, and a powerful camera. Using a 3D scanner with a kit like this could be a good solution if you need to create a highly accurate 3D model. The 3D point cloud created with photogrammetry can be aligned with the 3D mesh you obtain after 3D scanning the object – it is the combination of both which helps achieve higher accuracy.

Your next step depends on what the end goal of any reverse engineering process is to you. After scan data processing, you can either use your model for reproduction or continue analyzing and transforming it in a reverse engineering CAD program.

It is at this stage that you will be able to perfect or customize your digital model, which usually means detecting intricate flaws or asymmetries, modifying your model by adding new features or converting scanned 3D models into history-based feature models.

Fitting CAD primitives to your digital model beforehand allows you to easily export models as CAD objects for use in any reverse engineering software. Have a look at some of the best programs you can use to finalize your reverse engineering process.

Geomagic Design X

Geomagic Design X is the ultimate solution for turning 3D scan data into feature-based CAD models. Created with the combined knowledge and expertise of Rapidform and 3D Systems, this software has in recent years remained unrivaled. Whether you need to scan a physical object to create a new part or subassembly, or to completely remodel a part as a parametric model, this outstanding platform has much to offer. Geomagic Design X effortlessly (and automatically) creates planes, sketches, and features from scanned data. Feel free to export your CAD feature history to CAD software such as SOLIDWORKS, Solid Edge, Siemens NX Creo, Inventor, and Pro/Engineer to broaden your design possibilities and hone your model to perfection.

The Design X user interface is as intuitive as the SOLIDWORKS interface it was modeled after. A ribbon of icons across the top contains all the tasks you need: Points, Polygons, Regions, Alignment, Sketch, Exact Surfacing. On the left-hand side, you’ll find a list of the data you create – ponts, polys, surfaces, and sketches. The newest release of Geomagic Design X in 2022 brought in several useful new features, such as various sketch tools, enhancements to the LOft and Exact Surfacing Modeling tools, and replacing a target mesh.

Geomagic for SOLIDWORKS

A superstar in the reverse engineering scene, Geomagic for SOLIDWORKS is a professional plug-in designed by 3D Systems. Its mission is to help you turn your 3D scans into editable CAD objects in a seamless workflow. Mesh editing, point cloud processing, and automatic feature extraction are only some of the useful tools Geomagic for SOLIDWORKS offers. This plug-in is a complete scan-to-CAD solution which allows you to create 3D models for reverse engineering at lightning speed.

Geomagic for SOLIDWORKS is essentially a condensed version of Geomagic Design X, which opens directly in SOLIDWORKS. If you are a SOLIDWORKS user, you will find this especially convenient: You’ll be able to work with an interface you’re already familiar with while doing everything you need to do, all in one software.

Many 3D scanners are integrated with Geomagic for SOLIDWORKS, so you can easily import the existing scan data. The plug-in’s user experience remains straightforward, thanks to a familiar linear workflow and an intuitive toolbar. The data you end up with, whether an imported mesh or a point cloud, can be used for downstream work with Geomagic’s reverse engineering algorithms.

This plug-in is perfect for easily addressing challenges such as lost design data, lack of CAD drawings for an old part, or having to recreate any physical part that is worn or broken.

SpaceClaim

Image source: Ansys/YouTube

SpaceClaim is standalone software, designed to help engineers create solid bodies from scratch. Very efficient in handling STL files, SpaceClaim utilizes a direct modeling approach. You can easily refine noisy scans and modify scanned components you are unsatisfied with. The platform also enables you to remove any geometry problems and challenges commonly encountered when working with CAD operations, such as model editing or defeaturing.

For engineers who don’t have much time to learn sophisticated or traditional CAD systems, Ansys SpaceClaim is a great solution, as it provides you with tools like Skin Surface – a method for auto surfacing solid geometry from prismatic or authentic shapes. This, in turn, makes it possible to reconstruct surface data from very different scans, regardless of their integrity. You can also cut down simulation prep time and focus on simulation results instead.

An industry-level CAD tool, SpaceClaim will come in handy at any stage of your CAD workflow. With all possible file prep functionalities, the platform enables you to accelerate geometry preparation, proceed to analysis faster, and save time before simulation. If you don’t have the inclination to explore CAD systems in depth, this solution offers a gentle learning curve, which could be a good option for you.