The Use of Reverse Engineering for the Development of a Model Using Computer-Aided Design

Abstract The aim of this article was to investigate the potential of reverse engineering for developing digital 3D models based on real, worn mechanical components, particularly in cases where original manufacturer documentation is unavailable. The main research question concerned the effectiveness and accuracy of reproducing the geometry of a physical object using various 3D scanning technologies and CAD design tools. The subject of the study was a hydraulic cylinder ball – a worn, deformed component that could no longer be sourced on the market. Two types of 3D scanners were used in the study: a handheld device and a stationary system. Measurement data obtained from each scanner was processed in the VXelements software and then used to create precise models in the SolidWorks environment. Conventional measurements were also conducted and served as a reference point. Comparative analysis showed a high degree of consistency between the methods, with dimensional differences not exceeding 0.4 mm and 2°. The results confirm that reverse engineering, supported by 3D scanning and CAD design, is an effective solution for the individual reconstruction of technical components. The significance of the findings directly relates to industrial practice – particularly in the context of rapid prototyping, spare part reproduction, and maintenance support. The developed methodology can support the digitization and automation of engineering processes, particularly in the context of documentation management and preparation of manufacturing data. In this study, the geometry of a worn component was reproduced without attempting to reconstruct its original shape. The resulting CAD model reflects the current state of wear.