Digital reverse engineering (RE) as a concept has exploded in recent years due to advances in technology and a growing awareness of best practices among manufacturers. While its popularity continues to grow in many areas of design and manufacturing, there tends to be a perception of ‘one size fits all’ when it comes to RE solutions. From a practical perspective this perception is not accurate. Every RE project should be objectively evaluated to fully understand the intent and desired outcome, not only in terms of data requirements but the use of that data, in both upstream and downstream applications, to ensure digital continuity. This will help manage expectations and avoid frustration. RE is no different than any other project you might undertake: you need the right set of tools for the job.
In the big picture, RE is a subset of digital measurement, which is the driver behind other manufacturing applications, including quality inspection, tool building, and assembly guidance. When considering a digital RE strategy it is best to take a step back and look at your whole manufacturing enterprise, if for no other reason than to understand how choices you make might complement other applications or departments. Quite often companies have digital measurement assets available that are underused, thought to be outdated, or just forgotten. A perfect example is CNC CMMs. Most shops have at least one and many sit unused because they have old software and controllers or have been eclipsed by portable measurement devices. The fact of the matter is, these old devices are extremely accurate and well-built, and can be cost effectively upgraded to run the latest software.