REVERSE

ENGINEERING DEMONSTRATIONS

Senior Engineer - Design & Development

GTDMC, Pakistan

Syed Zillay Ali

WHAT IS REVERSE ENGINEERING?

A process of discovering thetechnological principles of ahuman made device, object orsystem through analysis of itsstructure, function and operation

Reverse Engineering Tools

3D-Printer

Laser sintering machine

CMM

3D-Scanner

3D LASER SCANNER

USED EXTENSIVELY FOR REVERSE

ENGINEERING

PROJECT-1

DIGITAL PARTS CATALOGUE

Engine Housing for an obsolete model of agricultural Tractor vehicle required

a complete set of Digital Drawings in order to ensure future repair and

maintenance / spares manufacturability.

The Project was taken as a challenge

Starting by making 3D Point Clouds Data, the final CAD models for a total of 11

components were accomplished in less than 60 days

Original part Point Cloud Data Model

PROJECT-2

CAD-TO-PART INSPECTION

CAD VS. Cloud Inspection using

PowerInspect® & Geomagic Qualify®

Point Cloud

Original CAD Model

Original part

• A Motorcycle Chassis Trim was manufactured using newly developed Toolings and it

was required to be inspected if it conformed to the original Design.

• So using 3D Laser Scanning, points-cloud data was generated and compared against

the original 3D CAD model.

• Variations were then traced and controlled.

• A sculpture of Mr. Muhammad Ali Jinnah (Quaid-e-Azam) – the Founder of

Pakistan, was 3D Laser Scanned. The points-cloud data was used to

produce a 3D CAD Model.

• The 3D CAD Model was then used to produce 10 replicas of the same

sculpture through SLS Rapid Prototyping methods.

Original Sculpture Point CloudRP Model

3D CAD Model

PROJECT-3

DIGITIZATION OF SCULPTURE

Baby Chair

Mold Machining

PROJECT-4MOULD DESIGN AND MANUFACTURE

Mud Flap Fuel tank Side mirror cover

Front Grill

PROJECT-5DIGITAL 3D CAD CATALOGUES

Racket HelmetPad

Hockey

PROJECT-6INNOVATIVE DESIGN CHANGES

ChairPlastic

PROJECT-7DIGITAL DESIGN DATA GENERATION FOR

LOAD ANALYSIS AND REINFORCEMENTS

TYPICAL WORKFLOW