Design & Reverse Engineering Services
Transform ideas or physical objects into precise digital models with The Manufacturing Collaborative’s comprehensive design digitization services. Our advanced 3D scanning capabilities and digital engineering expertise help manufacturers modernize legacy parts, accelerate product development, and ensure quality control through accurate digital representations.
What Is Manufacturing Digitization?
Digitization in manufacturing refers to converting physical parts, assemblies, and components into accurate digital models using advanced 3D scanning technology and computer-aided design (CAD) software. This process creates measurable, modifiable digital representations that serve as the foundation for reverse engineering, finite element analysis (FEA), quality inspection, and modern manufacturing workflows.
Our Digitization Capabilities
CT Scanning & Structured Light Scanning
Our state-of-the-art 3D scanning equipment captures complex geometries with exceptional precision:
- Structured Light Scanning: High-resolution surface capture for intricate details and complex geometries
- CT Scanning: Captures internal (hidden) features and external surfaces in one 3D image allowing further analysis and the creation of a Computer Aided Design (CAD) file.
- Scanning with Spin Table: 360-degree capture for complete part digitization
- Resolution: Accuracy down to micron-level detail depending on part size and requirements
- Part Size Range: From small precision components to large assemblies
- Materials: Scan metallic, plastic, composite, and various surface finishes
Applications:
- Reverse engineering of legacy parts without documentation
- Quality inspection and dimensional verification
- Creating digital twins for simulation and analysis
- Archiving critical components digitally
- Rapid prototyping preparation
Computer-Aided Design (CAD) & Reverse Engineering
Transform scan data into manufacturing-ready CAD models:
- 3D Model Reconstruction: Convert scan data into parametric CAD files (STEP, IGES, Parasolid formats)
- Surface Modeling: Create accurate surface representations from point cloud data
- Solid Modeling: Generate fully editable solid models for manufacturing
- Design Optimization: Improve upon original designs while maintaining form and function
- Documentation Creation: Generate manufacturing drawings and specifications from digital models
Industries Served:
- Aerospace & Defense
- Automotive
- Medical Devices
- Industrial Equipment
- Consumer Products
Finite Element Analysis (FEA)
Validate your designs and optimize performance through digital simulation:
- Structural Analysis: Assess stress, strain, and deformation under load
- Thermal Analysis: Evaluate heat transfer and thermal management
- Modal Analysis: Determine natural frequencies and vibration characteristics
- Optimization Studies: Reduce material usage while maintaining performance
- Failure Prediction: Identify potential weak points before physical testing
Benefits:
- Reduce physical prototyping costs
- Accelerate product development timelines
- Improve product performance and reliability
- Meet regulatory compliance requirements
- Support design validation and verification
Generative Design & Advanced Lattice Structures
Leverage AI-powered design tools to create optimized geometries:
- Topology Optimization: Generate lightweight structures that maintain strength
- Lattice Structure Design: Create complex internal geometries for additive manufacturing
- Multi-Objective Optimization: Balance weight, strength, cost, and manufacturability
- Integration with 3D Printing: Design specifically for metal and polymer additive processes
Why Choose TMC for Digitization Services?
Leading-Edge Technology Access
Access industrial-grade 3D scanning equipment without the capital investment:
- Nikon XT H 225 ST CT Scanner for internal inspection (5-100μm resolution)
- Advanced laser scanning systems for external geometry capture
- Professional CAD software including generative design capabilities
- FEA simulation tools for comprehensive analysis
Expert Engineering Guidance
Our experienced engineering team provides more than just scanning services:
- Application Engineering: Understand your specific challenges and recommend optimal solutions
- Process Consulting: Advise on best practices for scan-to-CAD workflows
- Quality Assurance: Ensure digital models meet your accuracy and tolerance requirements
- Integration Support: Help incorporate digitization into your existing workflows
Comprehensive Digital Engineering Solutions
Unlike standalone scanning services, we offer end-to-end digital engineering:
- Scan → Design → Analyze → Manufacture workflow
- Seamless integration with our 3D printing, CNC machining, and metrology services
- Single-source solution from concept to production
- Consistent quality across all phases of product development
Academic Affiliation & Research Capabilities
As part of Vermont State University, we bring additional value:
- Access to cutting-edge research and emerging technologies
- Collaborative problem-solving approach
- Educational resources and training opportunities
- Objective, unbiased technical recommendations
Common Digitization Applications
Reverse Engineering Services
The Challenge:
You have a physical part but no CAD files, drawings, or original design documentation.
Our Solution:
- High-precision 3D scanning captures complete geometry
- Point cloud processing and mesh generation
- CAD model reconstruction with parametric features
- Drawing creation with GD&T and tolerances
- Manufacturing-ready files for reproduction
Typical Use Cases:
- Obsolete parts requiring replacement
- Competitor product analysis
- Legacy equipment modernization
- Lost or incomplete documentation recovery
- Product improvement and redesign
Design Engineering Services
The Challenge:
You have an idea or invention that you need to convert to engineered models, drawings, or prototypes.
Our Solution:
- CAD model generation
- Rapid prototyping
- Design for manufacturability
- Design analysis and simulation
- Drawing creation with GD&T and tolerances
- Manufacturing-ready files for reproduction
Typical Use Cases:
- New designs from a napkin sketch
- New inventions or ideas
- Product improvement and redesign
Quality Inspection & Dimensional Verification
The Challenge:
Verify manufactured parts meet design specifications and identify deviations.
Our Solution:
- 3D scan of as-built parts compared to CAD model
- Automated deviation analysis with color maps
- Dimensional reporting against specifications
- Root cause analysis for manufacturing issues
- First Article Inspection (FAI) support
Benefits
- Faster inspection than traditional CMM methods
- Complete part geometry capture
- Visual deviation reports easy to understand
- Non-contact measurement eliminates damage risk
- Comprehensive documentation for quality records
Digital Twin Creation
The Challenge:
Create accurate digital representations of physical assets for simulation, monitoring, or archival.
Our Solution:
- High-fidelity 3D scanning of equipment or components
- CAD model development with accurate geometry
- Assembly modeling for complex systems
- Integration with simulation and analysis tools
- Digital archive for future reference
Applications:
- Equipment maintenance and planning
- Process simulation and optimization
- Training and visualization
- Spare parts manufacturing
- Facility planning and layout
Design Validation & Prototyping
The Challenge:
Verify prototype geometry matches design intent before moving to production.
Our Solution
- Rapid scanning of prototypes and mock-ups
- Comparison to original CAD models
- Iteration feedback for design refinement
- FEA analysis on as-built geometry
- Documentation for design reviews
Value:
- Catch design issues early in development
- Reduce costly tooling changes
- Accelerate design iteration cycles
- Improve communication between engineering and manufacturing
Digitization Process & Workflow
Step 1: Consultation & Planning
- Discuss your objectives and requirements
- Assess part geometry, size, and material
- Determine appropriate scanning methodology
- Establish deliverable specifications and timeline
- Provide project quote and timeline
Step 2: 3D Scanning
- Prepare part for optimal scan quality
- Execute scanning using appropriate technology
- Capture multiple orientations and perspectives
- Generate high-resolution point cloud data
- Perform initial quality check of scan data
Step 3: Data Processing
- Clean and filter point cloud data
- Generate mesh surface from point cloud
- Align multiple scans if required
- Perform dimensional verification
- Prepare data for CAD conversion
Step 4: CAD Model Creation
- Import processed scan data into CAD software
- Create parametric solid or surface models
- Add design features and intelligence
- Optimize geometry for intended use
- Generate manufacturing drawings if required
Step 5: Analysis & Validation (Optional)
- Conduct FEA or other simulation studies
- Compare scanned geometry to original specifications
- Generate inspection reports and documentation
- Provide design recommendations
- Review results with your team
Step 6: Delivery & Support
- Deliver CAD files in specified formats
- Provide inspection reports and documentation
- Offer integration support with your systems
- Available for follow-up consultation
- Support transition to manufacturing
Target Industries & Applications
Aerospace & Defense
- Reverse engineer legacy aircraft components
- Quality inspection of critical parts
- Lightweight structure optimization
- AS9100 compliance documentation
- First article inspection support
Automotive & Transportation
- Aftermarket part development
- Restoration of classic vehicles
- Performance part optimization
- Quality control and metrology
- Tooling and fixture design
Medical Devices
- Custom implant and prosthetic design
- Reverse engineering of surgical instruments
- Biomechanical analysis and simulation
- Regulatory submission support
- Patient-specific device development
Industrial Equipment
- Replacement parts for obsolete machinery
- Equipment modernization and upgrades
- Failure analysis investigation
- Preventive maintenance planning
- Retrofit component design
Research & Academia
- Non-destructive analysis of artifacts
- Material characterization studies
- Biomechanical research support
- Proof-of-concept development
- Educational applications
Technical Specifications
Scanning Capabilities
Laser Scanning System:
- Technology: Structured light and laser triangulation
- Accuracy: ±0.025mm to ±0.100mm depending on part size
- Scan Speed: High-speed capture for efficient turnaround
- Part Size: 10mm to 2000mm diagonal
- Surface Finish: Handles reflective, dark, and complex surfaces
CT (Computed Tomography) Scanning:
- Equipment: Nikon XT H 225 ST
- Resolution: 5-100μm
- Volume Graphics software analysis
- Applications: Internal inspection, porosity analysis, weld inspection, assembly verification, root cause failure analysis
- Non-destructive evaluation of internal features
File Formats & Deliverables
Scan Data Outputs:
- Point Cloud: .xyz, .asc, .pts, .ply
- Mesh: .stl, .obj, .ply, .wrl
- Inspection: .pdf reports with color deviation maps
CAD Model Outputs:
- Native: SolidWorks (.sldprt, .sldasm)
- Universal: .step, .iges, .parasolid, .sat
- Drawing: .pdf, .dxf, .dwg
Analysis Outputs:
- FEA Results: Native solver formats
- Reports: .pdf technical documentation
- Visualizations: Images and animations
Turnaround Times
- Standard Scanning: 3-5 business days
- CAD Model Development: 1-2 weeks typical
- FEA Analysis: 1-2 weeks depending on complexity
- Rush Services: Available upon request for urgent needs
Note: Exact timing and pricing determined during consultation based on your specific requirements.
Frequently Asked Questions
What's the difference between 3D scanning and CT scanning?
3D Laser/Structured Light Scanning captures external surface geometry using optical methods. It’s ideal for reverse engineering, inspection of outer surfaces, and creating visual models.
CT (Computed Tomography) Scanning uses X-rays to capture both internal and external geometry non-destructively. It’s essential for inspecting internal features, assemblies, voids, and hidden defects.
We use both technologies depending on your application requirements.
How accurate are your 3D scans?
Our scanning accuracy ranges from ±0.025mm to ±0.100mm depending on part size, geometry complexity, and surface characteristics. CT scanning offers 5-100μm resolution for internal features. We’ll recommend the appropriate technology to meet your tolerance requirements.
Can you scan reflective or shiny parts?
Yes. While reflective surfaces can challenge some scanning systems, we use powder coating and specialized techniques to capture accurate geometry from metallic, glossy, and transparent materials.
Can you design parts from a sketch or idea?
Yes, we can convert your idea into a CAD model, drawings and prototypes. The digitized design is important to advance your design idea and convert it into necessary formats for modern manufacturing
What file formats do you deliver?
We provide files in industry-standard formats including STEP, IGES, STL, Parasolid, and native SolidWorks formats. We can accommodate most CAD system requirements.
Do you provide engineering analysis with digitization?
Yes. We offer FEA simulation, design optimization, design for manufacturing, and engineering consultation as part of our comprehensive digital engineering services. This helps ensure your digitized models perform as intended.
Can you handle confidential or proprietary parts?
Absolutely. We maintain strict confidentiality agreements and offer NDAs upon request . Our facility supports secure handling of sensitive materials.
How do digitization services integrate with manufacturing?
Our digitization services seamlessly connect with our other capabilities including 3D printing, CNC machining, and metrology. We can take your parts from scan-to-production in a single facility with consistent quality.
Getting Started with Digitization Services
Request a Quote
Contact our team to discuss your digitization needs:
- Email: [email protected]
- Location: Vermont State University, Randolph Campus
What to Prepare
For accurate quoting, please provide:
- Description of parts or components to be digitized
- Approximate size and material
- Intended use of digital models
- Required accuracy and detail level
- File format preferences
- Project timeline and deadlines
On-Site Consultation Available
For complex projects or multiple parts, we offer:
- Virtual consultations to assess feasibility
- On-site visits for large assemblies (within Vermont/New England)
- Sample scanning to demonstrate capabilities
- Technical recommendations and process planning