Professional Reverse Engineering Services
Transform physical parts into fully editable CAD models. Perfect for obsolete parts, discontinued components, and legacy equipment. Based in Modesto, CA - we ship anywhere in the United States.
What is Reverse Engineering?
Reverse engineering is the process of analyzing an existing physical part and recreating it as a fully editable, parametric CAD model. Unlike simple 3D scanning which only produces a mesh file (STL), reverse engineering delivers production-ready CAD files in formats like STEP, IGES, Solidworks, or Fusion 360.
This service is essential when you need to reproduce a part but don't have the original CAD files - whether it's an obsolete component, a discontinued product, or a part where the original design files were lost or never existed.
Our reverse engineering process combines high-precision 3D scanning (accurate to ±0.05mm) with expert CAD modeling to create fully editable designs that match your original part's form, fit, and function.
When You Need Reverse Engineering
Obsolete or Discontinued Parts
Equipment manufacturer went out of business or discontinued the part? We scan your existing part and recreate it digitally, allowing you to 3D print replacements or send to a machine shop for manufacturing.
Lost or Missing CAD Files
Original design files lost in a computer crash, company acquisition, or file format obsolescence? We recreate the CAD model from your physical part with all dimensions and features intact.
Design Improvements & Modifications
Need to improve an existing design but don't have editable files? We reverse engineer the part, then you can modify dimensions, add features, or optimize for different manufacturing methods.
Legacy Equipment Documentation
Create digital archives of critical parts for long-term equipment maintenance. Future-proof your spare parts inventory with CAD files ready for on-demand manufacturing.
Quality Control & Inspection
Compare as-manufactured parts to original specifications. Create inspection reports showing dimensional variations and tolerances for QC purposes.
Our Reverse Engineering Process
Part Submission & Analysis
You send us the physical part (or bring it to our Modesto, CA location). We analyze the part's geometry, material, and critical features to determine the best scanning and modeling approach.
Timeline: Same day review and quote
High-Precision 3D Scanning
Using professional-grade 3D scanning equipment (±0.05mm accuracy), we capture every surface, curve, and feature of your part. The scan produces a dense point cloud that serves as the foundation for CAD modeling.
Timeline: 1-2 hours depending on part complexity
Parametric CAD Modeling
Our experienced CAD engineers recreate the part in professional CAD software, building fully editable, parametric models with proper constraints and design intent. Unlike auto-converted meshes, these models are clean, editable, and ready for manufacturing.
Timeline: 3-5 days for standard parts
Quality Verification
We overlay the CAD model on the original scan data to verify dimensional accuracy. Critical dimensions are measured and documented to ensure the model matches your original part within specified tolerances.
Timeline: 1 day
File Delivery
You receive the final CAD files in your preferred format: STEP, IGES, STL, Solidworks, Fusion 360, Inventor, or other standard formats. Files include both the parametric model and export formats compatible with your manufacturing processes.
Timeline: Same day after approval
Rush Service Available
Need it faster? We offer rush service with 2-3 day turnaround for urgent projects. Emergency same-day service may be available for local customers - call (256) 322-3403 to discuss your timeline.
Technical Specifications
Scanning Capabilities
- Accuracy: ±0.05mm (0.002")
- Part size: 10mm to 500mm
- Material compatibility: Most surfaces
- Complex geometries supported
- Internal features (with access)
CAD File Formats
- STEP (.stp, .step)
- IGES (.igs, .iges)
- Solidworks (.sldprt)
- Fusion 360 (.f3d)
- STL (for 3D printing)
- Parasolid (.x_t, .x_b)
- Other formats available
Industries We Serve
Manufacturing & Industrial
Replacement parts for production equipment, tooling reproduction, legacy equipment documentation
Aerospace & Defense
Legacy aircraft parts, discontinued components, quality control and inspection
Automotive
Classic car parts, aftermarket development, OEM part replication for restoration
Medical Device
Legacy medical equipment parts, custom surgical guides, prototype development
MRO (Maintenance, Repair, Operations)
Emergency replacement parts, equipment downtime prevention, spare parts inventory
Product Development
Competitor analysis, design improvement, patent research, quality benchmarking
Frequently Asked Questions
How accurate is your reverse engineering?
Our 3D scanning achieves ±0.05mm (0.002") accuracy, and our CAD models match the original part within those tolerances. For critical dimensions, we can verify specific features to even tighter tolerances. We provide dimensional inspection reports comparing the CAD model to the scan data.
Do I need to send you the physical part?
Yes, we need the physical part for accurate 3D scanning. You can ship it to us (we'll ship it back after scanning) or bring it to our Modesto, CA location for same-day scanning. For extremely large parts, we may be able to come to your location - contact us to discuss.
What if my part is broken or damaged?
We can often work with damaged parts! We scan what remains and use our engineering experience to reconstruct missing or damaged features. We'll work with you to understand the original design intent and recreate the complete part. Photos of the undamaged part are very helpful if available.
Can you reverse engineer assemblies with multiple parts?
Absolutely! We can scan and model entire assemblies, including proper mating relationships between components. Each part is modeled separately, then assembled with appropriate constraints. This is ideal for recreating complex mechanisms or documenting legacy equipment.
What's included in the final deliverables?
You receive: (1) Parametric CAD model in your preferred format, (2) STL files ready for 3D printing, (3) Technical drawing/dimensional report (if requested), (4) Original scan data (mesh file), and (5) Inspection report showing dimensional accuracy. All files are yours to use without restrictions.
How much does reverse engineering cost?
Pricing starts at $200 for simple parts and varies based on complexity, size, and required accuracy. Most projects range from $200-$1,500. We provide a fixed quote upfront after reviewing your part (photos or in-person), so there are no surprises. Rush service adds 30-50% to the base price.
Do you offer rush service?
Yes! Rush service (2-3 days) and emergency service (24-48 hours) are available for urgent projects. Contact us at (256) 322-3403 to discuss your timeline. For local customers in Modesto, same-day scanning with expedited modeling may be possible depending on part complexity.
Can you also 3D print the part after reverse engineering?
Absolutely! Many customers use our complete service: reverse engineering + 3D printing. We can print prototype parts for testing, functional replacement parts, or production quantities. We'll optimize the CAD model for 3D printing to ensure the best results. See our Rapid Prototyping and Industrial 3D Printing services for more details.
Get Started Today
Free quote within 24 hours. No obligation.
Request Free Quote (256) 322-3403📍 Based in Modesto, CA
🚚 Ship Anywhere in USA
Pricing
*Final pricing based on part complexity, size, and required accuracy. Fixed quote provided upfront.