What is Reverse Engineering and Why is it Important?

Put simply, reverse engineering is taking something apart to determine exactly how it was made without having a blueprint to follow, or to derive or duplicate the design, technical specifications, manufacturing methods, or functionality of an object by studying an existing product, prototype, etc. Reverse engineering is the opposite of conventional engineering—instead of designing first and then building the product, reverse engineering collects a product and builds a design based on its dimensions and GD&T features.

Reverse engineering leads industries to produce the best products because it increases competition. The cycle goes on as engineers continuously try to be the next best version.

The boost of being the next-best is valuable for industries like the medical industry. With reverse engineering pushing engineers to manufacture the next best orthopedic and orthodontic devices, the industry rapidly evolves and gives the best devices for patient care.

The aerospace industry is another industry that has significantly evolved because of reverse engineering. Engineers are competing to make the most durable, safe, and high-functioning aircraft components—increasing aircraft safety and efficiency by the day.

The practice benefits consumers, and it also benefits companies, too. The constant innovations drive companies into success and an evolving market. Reverse engineering at a company’s disposal means that there are growth opportunities for any competitor product.

The reverse engineering definition is simple, but the process is more complex—it’s not just taking something apart and looking at its components. There are three steps to the reverse engineering process.

Thanks to new practices and different types of CMM machines, reverse engineering applications have expanded quite a bit in manufacturing.

Common reverse engineering examples in manufacturing include:

• Creating data to effectively replace legacy parts that other manufacturers don't create anymore.
• Help with failure analysis and determining why another part or machine broke down or failed in its processes.
• Trial and error can offer insight into how a product or part can be improved.
• In some cases, the reverse engineering process is a necessity for repairing specific parts or other machines.

Depending on how reverse engineering examples are applied, manufacturers can reap several benefits. The bullet points below offer a comprehensive answer to the question: What is reverse engineering?

• It can help to address weak points in intellectual property.
• Offers a separate look at how something might need to be repaired.
• Helps lead to products that offer more interoperability across other components and systems.
• It can add to cost reduction as it helps to avoid creating new components entirely from scratch.
• There will always be a competitive advantage involved with utilizing the process to enhance products and develop new ones.

When reverse engineering, engineers follow two popular processes: drawings and scanning. Both of these methods use CAD models for the prototyping process but differ in how the CAD model is created.

CAD files are an integral part of reverse engineering. Using these makes it much easier for engineers to follow modeling without 2D distortion.

Engineers upload data into CAD files, which then create a 3D wireframe. Engineers use the wireframe to expand upon the original model. These files are manipulated with drawings, printing, and modeling.

Out of these three CAD files, there are differences in how they store data and how engineers access it. Let’s get into the specifications.

The use cases for reverse engineering in manufacturing are extensive, and legal and ethical considerations are frequently involved. Companies have used the practice to steal technology and trade secrets for their own gain, which is why numerous countries have strict regulations.

The scope of these details varies around the world, but there are two main things to consider in the U.S. before attempting to reverse engineer a product. In general, this process is allowed under the Defend Trade Secrets Act (DTSA).

• It is legal if the original version is legally obtained. Improper means include theft, bribery, and misrepresentation.
• It is legal if no contractual agreements are violated.

Reverse engineering is rapidly adapting and changing. New innovations are continuous, and engineers have millions of opportunities to recreate products in a more cost-effective, usable, and advanced way. The weight of opportunity is inspiring but also daunting when businesses feel like they can’t keep up with new technologies. Luckily, leading systems and machinery can make this process easier and more cost-effective to implement.

At KEYENCE, we offer coordinate measurement machines, the XM and the WM Series, that collect measurement data in an instant. These machines create data point clouds similar to the scanning method of reverse engineering.

The XM and WM touch probe CMMs are handheld and require virtually no training to use. With the press of a button, these devices collect GD&T data points in seconds, create point clouds from free-form capture, and export DXF, STP, and IGES files. These files then turn into full 3D models in CAD software.

With KEYENCE’s CMMs, you’ll have the tools to become a reverse engineering leader with industry-proven equipment. Contact us today to get your hands on a CMM or to discuss your reverse engineering needs.