Reverse Engineering Software
& Operations
Software Classification
RE software varies by project needs: hardware control, CAD, polygons, NURBS,
2-D/3-D imaging, and inspection.
RE Phases
Four phases: points/images, polygon, curve, and NURBS surface construction.
Key Operations
Data registration, noise reduction, polygon optimization, curve fitting, and
NURBS patch editing.
Applications
Used in inspection, product development, medical modeling, graphics, and
heritage documentation.
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--- Fahmida Tabassum
IPE 4671 Reverse Engineering – Fahmida Tabassum Bristy
Upcoming Topics
Next, we will explore advanced algorithms in reverse engineering software.
We will also discuss integration techniques and real-world case studies.
Advanced Algorithms Software Integration Case Studies
Explore cutting-edge methods Learn how to connect RE Review practical applications
for data processing and software with CAD and and success stories from
modeling. manufacturing tools. various industries.
IPE 4671 Reverse Engineering – Fahmida Tabassum Bristy
Destructive Method
• The destructive RE process is the reverse of this. To
remodel the part, 2-D slice images of the part are
gathered by destroying the part layer-by-layer.
• The data acquisition procedure of a destructive
system is presented in Fig- ure 3.11. The
disadvantage of this method is the destruction of
the object. How- ever, the technique is fast. The
accuracy is acceptable; the repeatability is
• ±0.0127mm (CGI systems). The layer thickness is
from 0.0127–0.254mm. The method allows
Figure 3.11. A procedure for data acquisition in a destructive RE system. (a)
capturing internal structures. In addition, a
The part and matrix combina- tion is embedded in a contrasting colored destructive systemcan work with any machinable
plastic matrix. (b, c) The part is machined layer-by-layer to expose the object, including parts made from aluminum alloys,
cross-sectional images. (d) The newly exposed surface of the part. A color
plastics, steel, cast iron, stainless steel, copper,
reproduction of this figure can be seen in the color section (pages 219–230).
and wood
IPE 4671 Reverse Engineering – Fahmida Tabassum Bristy
Reverse Engineering Softwares
IPE 4671 Reverse Engineering – Fahmida Tabassum Bristy
Reverse Engineering Softwares
No. Application Main functions Software
1 Hardware control Control RE hardware for data acquisition. Normally, basic data Mitutoyo Cosmos, Hymarc, Metris Scan, Cyberware
processing operations and data conversion are also provided. CyDir and
GSI Crystal Studio.
2 CAD entity manipulation Manipulate CAD entities that are extracted from point clouds ICEM surf, Imageware and other common CAD
and polygon meshes. CAD entities include points, contour packages such as UG, Pro Engineer and Solidworks.
lines, and CAD primitives such as circles, rectangles,
cylinders, and boxes.
3 Polygon manipulation 3-D polygon data editing, modification, and optimization. Magics RP, DeskArtes, Catia Shape Sculptor and
Viscam RP.
4 Polygon and NURBS surface Provide a complete set of RE data processing tools from GSI Studio, CopyCAD, Rapidform, Geomagics,
construction working with point clouds and polygons to constructing Polyworks (Modeler) and Paraform.
NURBS surfaces as well as 3-D inspection.
5 2-D Scan Image Processing Used for processing 2-D scan images (CT/MRI) and Mimics, Rapidform, BioBuild, Velocity2, Amira, Scan
and 3-D modeling 3-D reconstruction. IP, Analyze and
3-D Doctors.
6 3-D Inspection Used for 3-D inspection, error map creation and analysis, COMETinspect, Metris Fo- cus Inspection, Power
inspection report and documentation. INSPECT, PolyWorks Inspector and Geomagic
Qualify.
7 NURBS surface and solid Provide NURBS modeling and editing tools based on basic Pro Engineers, UG, Solidworks, Catia and Rhino.
modeling
CAD entities and primitives.
IPE 4671 Reverse Engineering – Fahmida Tabassum Bristy
Reverse Engineering Phases
IPE 4671 Reverse Engineering – Fahmida Tabassum Bristy
Fundamental Reverse Engineering
Operations
Data Registration Data Optiization
Capturing accurate measurements via scanning or Cleaning and organizing raw data for further
probing devices. modeling.
Optimizing Polygon Models Editing and Controlling Polygon Models
Converting processed data into geometric CAD Ensuring model accuracy by comparing with original
models or surfaces. objects.
IPE 4671 Reverse Engineering – Fahmida Tabassum Bristy
Data Registration
• Multiple scans are needed to capture a full 3-D model, because a
single scan can miss hidden or occluded areas.
• Each scan produces its own point cloud; these clouds start out mis-
oriented relative to one another.
• Data registration aligns and merges all point clouds into one common
coordinate system—crucial before any further reverse-engineering steps.
• Two registration methods:
• Manual alignment: pick matching landmark points on a “fixed” and
a “floating” cloud, then translate/rotate the floating one to match.
• Automatic alignment: software iteratively adjusts clouds until the
overall error (tolerance) falls below a set threshold. Figure: a) The first point cloud with three
landmark points (P1, P2, and P3). (b) The
• After manual alignment, automatic fine-tuning usually follows to achieve second point cloud with three landmark
points (PP1, PP2, and PP3) that correspond to
optimal accuracy. those of the first point cloud.
• If coverage or tolerances are inadequate, acquire extra scans or refine (c) The resulting point cloud after
registration. A color reproduction of this
scanning strategies, and optimize point clouds/meshes before re-running figure can be seen in the Color Section
registration. (pages 219–230)
IPE 4671 Reverse Engineering – Fahmida Tabassum Bristy
Data Optimization Noise & Point Redundancy
Reduction
• Scans carry errors: stray points, overlaps, duplicates after registration.
• Noise-reduction tools (manual or automatic) reposition points
statistically, keeping sharp edges on mechanical parts or
smoothness on organic ones.
• Redundancy reduction thins out clusters of nearly coincident
points to trim file size and speed processing.
Sampling Points
• Cuts point-count and imposes structure for easier handling.
• Curvature sampling: spares more points in high-curvature
zones to preserve detail.
• Random sampling: removes a user-set percentage uniformly at random.
Identifying Primitives • Uniform sampling: divides space into cubic cells, keeps one point per cel
• Fits perfect planes, cylinders, spheres, etc., to mechanical shapes.
• Corrects noisy scan areas and sets strong geometric
references for later modeling.
IPE 4671 Reverse Engineering – Fahmida Tabassum Bristy
Polygon Phase
Optimizing Polygon Models
• Noise reduction & cleaning: smoothes surfaces
or sharpens edges while respecting curvature
statistics; multiple strength levels.
• Abnormal-face cleaning: fixes non-manifold,
redundant, or intersecting faces.
• Mesh refinement: subdivides triangles to add
detail and smoothness. Figure 3.21. (a) A horse model with 2500 triangles created by
applying polygon decimation to (b) the same model with
6000 triangles
• Mesh decimation: deletes triangles intelligently
to lighten the model without visible loss.
IPE 4671 Reverse Engineering – Fahmida Tabassum Bristy
Polygon Phase
Editing & Controlling Polygon
•
Models
Hole filling: remeshes gaps with curvature-
matched patches.
• Defeaturing: deletes unwanted bumps/slots, refits
area with smooth triangulation.
• Edge Detection and Sharpening Control
• Scanning devices are often unable adequately to
capture sharp features, such as creases or mechanical
edges. When transforming to a polygon mesh, these Figure 3.22. Images before (a) and after (b) the hole filling
features are usually filleted or rounded. This operation operation
reproduces an edge by redefining it mathematically and
then extending the polygon model to that newly defined
sharp edge.
• Primitives Fitting
• The primitives fitting operation fits selected regions to
primitives such as planes, cylinders, and spheres. It is
especially useful for mechanical parts.
IPE 4671 Reverse Engineering – Fahmida Tabassum Bristy
Polygon Phase
• Edge Detection & Sharpening • Boundary Control & Editing
• Scanners round off creases; this tool re-defines edges • Repairs ragged open edges: mark, add/move control
mathematically and pulls the mesh out to those crisp points, straighten, smooth, fit to primitives/paths, or
lines. project to planes; surrounding mesh auto-adjusts.
• Primitives Fitting • Basic Polygon Operations
• Snaps selected mesh regions to perfect planes, • CAD-style tools: Boolean (union/subtract/intersect),
cylinders, spheres—handy for mechanical parts. trim, shell, offset, thicken, cut, mirror, rotate, move,
• Polygon Editing & Remeshing (triangle-level control) datum control.
• Split edge – divide one edge, add two triangles.
• Flip edge – pivot an edge within its quad patch.
• Contract edge – collapse an edge, removing a triangle.
• Add triangle – insert a new face from three picks.
• Remesh – re-optimize triangles toward equilateral shapes.
IPE 4671 Reverse Engineering – Fahmida Tabassum Bristy
Curve Phase
•NURBS surfaces are built from a network of curves, often derived from point
clouds or polygon models for free-form parts.
•Basic CAD entities (e.g., circles, lines) can be manually fitted using reference
points.
Key Operations:
•Cross Sectioning: Creates curves/points by intersecting the model with a
plane.
•3D Curve Fitting: Generates curves from a set of points.
•Curve Modification: Adjusts curves for modeling needs.
Curve Modification Tools:
•Reparameterization: Changes number/distribution of control points.
•Degree Conversion: Alters curve degree within tolerance.
•Smoothing & Cleaning: Refines curves by removing excess control points.
IPE 4671 Reverse Engineering – Fahmida Tabassum Bristy
Curve Phase (NURBS Surface Phase)
• Cross-Sectioning – slice the model with planes to get profile
curves.
• 3-D Curve Fitting – build a curve directly through point sets.
• Curve Modification Toolkit
• Re-parameterize (add/redistribute control points).
• Degree convert (raise/lower order within tolerance).
• Smooth/clean (remove noise & extra points).
• Control-point edit (manual shape tweaks).
• Point generation (spawn evenly/randomly spaced points from
a curve).
• Redirect, transition, extend (reverse direction, stitch curves,
lengthen with tangent/curvature continuity).
IPE 4671 Reverse Engineering – Fahmida Tabassum Bristy
Conclusion
• RE Toolbox Overview • Key Hardware Specs to Compare
• Wide range of hardware/software now tackles both external • Volume / Field-of-View
and internal geometry. • Accuracy
• Picking the “right” combo hinges first on the application. • Acquisition Speed
• Common Application Domains • Software Reality Check
1. Inspection / QC – dimensional checks on parts & assemblies. • No single package covers the entire RE workflow.
2. Product Dev & Manufacturing – CAD-CAM-CAE loops, • For polygon-only tasks (QC, prototyping, animation), one
rapid prototyping/tooling. suite may suffice.
3. Biomechanics & Medicine – bone studies, patient- • For full product-development pipelines, expect two tiers:
specific models, implants, surgical guides.
1. RE data manipulation (point-cloud ↔ polygon
4. 3-D Graphics & Animation – VR, games, film assets. handling).
5. Fashion & Arts – digital sculpting, garment protos, artistic 2. Geometric modeling (CAD or NURBS surfacing built
models. from that data).
6. Topography & Heritage – building facades, as-built
surveys, archaeology, city models.
IPE 4671 Reverse Engineering – Fahmida Tabassum Bristy