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    Engineering Design Services

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  • Reverse Engineering Pneumatic

    Steel Strapping Machine

    Reverse engineering is essentially an important method to

    identify flaws in the existing design of the product and

    improve the design subsequently, without major investment

    in cost and time. It is crucial to figure out the potential

    design errors in the product leading to premature failure.

    Apart from competitive benefits, the reverse engineering

    process imparts manufacturers with comprehensive design

    information of their product, from which further innovation

    can be accomplished

    A leading tools manufacturer from the US approached Hi-

    Tech to reverse engineer steel strapping machine, which

    possessed a design flaw that led to premature failure. The

    client needed to investigate the problem through simulation

    and needed a design solution to overcome the early failure


    The steel strapping machine prototype was transformed into

    digital CAD model using 3D scanning technique and

    manual measurements. To reverse engineer the machine,

    individual components were disassembled and respective

    geometrical information was recorded to obtain accurate

    overall design of the machine. Individual component

    drawings as well as detailed manufacturing drawings were

    prepared. The components were then analyzed separately

    for structural integrity and stress concentration to identify

    critical areas in design requiring optimization.

    Based on the analysis results obtained, it was observed that

    two of the machine components needed modification in

    design in order to sustain stress levels resulting during the

    machine operation. Modifications in the design were made

    and the new design of the machine was proposed with

    better ergonomics and strength against loads to withstand

    premature failure.

    Competitive advantage in the market with improved

    product design

    30% reduction in prototyping test trials

    Identified major design flaws with reduced turn around

    and faster time to market

    Digital design documentation for future modification in








    To reverse engineer steel strapping machine for

    design optimization and document design

    information digitally

    Tools Manufacturer, USA



    capture accurate geometrical dimensions

    =Performing manual dimension measurements to

    obtain missed-out geometrical information

    during the 3D scanning process

    =Developing CAD models, 3D and 2D detailed

    drawings for manufacturing purposes

    =Evaluating the design for stress concentration

    and performing subsequent optimization to

    propose better design of the strapping machine

    3D scanning complex machine geometry to


    The CAD model of the steel strapping machine was

    developed using 3D scanning technique and

    manual dimension measurement. In order to

    reverse engineer, the machine was disassembled

    sequentially to capture accurate geometric

    information of each individual component. The final

    design obtained was utilized to perform structural

    analysis for identification of stress concentration.

    Based on the analysis results, the design was

    optimized to withstand high stress values without


    Case Study Highlights


    Client Profile:

    About Hi-Tech

    Hi-Tech CADD, a division of Hi-Tech Outsourcing Services, provides concept to manufacturing and post-

    manufacturing engineering solutions to organizations across the globe. Their team of expert design engineers, CAD

    professionals and CAE analysts operate out of a well-established base in India and USA. Their design facility is

    equipped with world-class infrastructure, hardware and software capabilities, to address complex engineering

    problems with least turnaround time.

    Author: Gaurang Trivedi

  • Hi-Tech Outsourcing Services

    Santa Clara, CA 95054

    547 Moreland WayPhone:



    Your Trusted Outsourcing Partner

    Copyright 2014 Hi-Tech Outsourcing Services All Rights Reserved

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