Reverse engineering is the process of taking an existing part and figuring out exactly how it was made — so you can recreate it, improve it, or integrate it into a new design. Whether you’re replacing a worn-out machine component, digitizing an old part, or adapting something for modern manufacturing, reverse engineering can save time and money.
At ADB Consulting, based in South Africa, I help clients worldwide with CAD-based reverse engineering, turning physical parts into accurate, production-ready 3D models.
What Is Reverse Engineering?
Reverse engineering involves measuring, analyzing, and recreating a physical object digitally. This can be done manually with precision tools or using advanced methods like 3D scanning.
Common reasons to reverse engineer:
- Replacing obsolete parts with no existing drawings
- Modifying parts to improve performance or fit
- Converting legacy designs to modern CAD formats
What are the steps involved in reverse engineering?
Reverse Engineering can be a difficult and time consuming process, which is why we at ADB Consulting follow a fixed set of steps to get our deliverables out on time, every time.
Assess
Investigate as much as possible and ask: Where is this part used? How is it used? Expected wear and tear must is endure? How is the surrounding conditions? What is the environment like?
Understanding where and how the part need to function is paramount to any reverse engineering part.
Be sure to take as many pictures as you possible can… I mean it… So many pictures. With scaled items for reference, head on, side view etc. If you can’t bring the part with you or scan it right there, then pictures are going to be your best friend!
Processes
Now’s time to think about how you’re going to make this part. Was it milled? Cast? Cut? What tools do you have? Any downsides to doing it differently? Now is the time to start reigning in your limitations and seeing what can and cannot be done. This will define how you design your part.
Design
Start thinking of a design and refine it. On paper, on a whiteboard, anywhere on the computer. If you cannot draw it on paper or see it in your mind in full detail, then go back to the drawing board. You need to be able to describe the part exactly and know precisely how it’ll be built. Reimagining something is infinitely faster than changing the design.
CAD Time
Now that you have the part in your mind and fully designed, NOW you can go to your favourite CAD program and start designing the part. It is important that going to the computer is the last step in your reverse engineering journey as this is often where most people waste most of their time!
CAD Design should be the process of taking a predefined design onto a computer, not for design iteration.
Tools & Techniques Used in Reverse Engineering
- Precision measuring tools (calipers, micrometers, CMM)
- CAD software for detailed modeling
- 3D scanning for complex geometries
- DFM analysis to make the part production-ready
Why Work With Me?
Based in South Africa, I combine hands-on manufacturing knowledge with advanced CAD skills. I’ve worked with sheet metal, machining and 3D printing — so I design with production in mind from the start. Whether you’re in Johannesburg, Cape Town, Durban, or abroad, I can deliver accurate, ready-to-manufacture CAD files and assist with parts production.