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Reverse engineering (RE) is the process of developing a complete set of drawings and specifications for a product from the examination and measurement of an existing object, analysis of available engineering data, and application of engineering judgment.

The data package must be sufficiently complete to allow a competent manufacturer to reproduce the item or system without additional information. The completeness of the data package is verified by the production of prototypes of the furnished items or systems. The methods used to produce the prototypes are identical to those employed for production of the reverse engineered items or systems. Although reverse engineering of an item or system superficially appears to be a simple task – just reproduce an existing item or system – closer examination of the concept of reverse engineering reveals many hidden pitfalls.

Southwest Research Institute (SwRI) provides the following services to assist clients with their reverse engineering needs:

Component and Application Reviews

• Components requirements, geometrical, functional, and performance

• Functionality/performance of the original component

• Operating environment

Part and Assembly Inspection

• Existing hardware – new or used

• Related assemblies for critical interfaces

Feasibility Study

• Data availability

• Acceptable schedule

• Technical feasibility

• Economic analysis

Documentation Review

• Component specification and requirements

• Design reports

• Operator/maintenance manual

• Maintenance records review

• Test reports

Dimensional Analysis

• Standard measurement tools

• 3D scanning

• Coordinate measuring machine

Materials Analysis

• Materials identification software

• Scanning electron microscope

• Material processing determination

Generate Part Geometry

• 3D solid geometry

• Finite element analysis redesign

• Part improvements desired

• Generate rapid prototype model for visualization

Fabrication

• 2D fabrication prints

• Production verification

• Prototype inspection

• Fit check

• Functional testing

Testing

• Existing component test

• Qualification test

• Prototype test

• Acceptance test

Reverse Engineering Deliverables

• Completed RE part

• Rights of ownership

• Material specifications

• Production drawings prototypes

• Design/test report

SwRI experience includes ground support equipment, flight critical parts and systems, power transmission parts, land gear components, missile parts and systems, motors, and support for industrial equipment. This work is done for both commercial and military clients.

For more information about reverse engineering capabilities at SwRI or how you can contract with SwRI, please contact Greg Wattis at gwattis@swri.org or (210)

522-2333.
 

| Structural and Mechanical Engineering Department | Mechanical & Materials Engineering Division | SwRI Home |

Southwest Research Institute® (SwRI®), headquartered in San Antonio, Texas, is a multidisciplinary, independent, nonprofit, applied engineering and physical sciences research and development organization with 11 technical divisions.

June 26, 2008