A Review on Reverse Engineering for Sustainable Metal Manufacturing: From 3D Scans to Simulation-Ready Models

Reverse engineering (RE) has been increasingly adopted in metal manufacturing to digitize legacy parts, connect “as-is” geometry to mechanical performance, and enable agile repair and remanufacturing. This review consolidates scan-to-simulation workflows that transform 3D measurement data (optical/laser scanning and X-ray computed tomography) into simulation-ready models for structural assessment and manufacturing decisions, with an explicit focus on sustainability. Key steps are reviewed, from acquisition planning and metrological error sources to point-cloud/mesh processing, CAD/feature reconstruction, and geometry preparation for finite-element analysis (watertightness, defeaturing, meshing strategies, and boundary condition transfer). Special attention is given to uncertainty quantification and the propagation of geometric deviations into stress, stiffness, and fatigue predictions, enabling robust accept/reject and repair/replace choices. Sustainability is addressed through a lightweight reporting framework covering material losses, energy use, rework, and lead time across the scan–model–simulate–manufacture chain, clarifying when digitalization reduces scrap and over-processing. Industrial use cases are discussed for high-value metal components (e.g., molds, turbine blades, and marine/energy parts) where scan-informed simulation supports faster and more reliable decision making. Open challenges are summarized, including benchmark datasets, standardized reporting, automation of feature recognition, and integration with repair process simulation (DED/WAAM) and life-cycle metrics. A checklist is proposed to improve reproducibility and comparability across RE studies.