Reverse Engineering & Rapid Prototyping


Dr. G. Arun Manohar


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Course Name : Reverse Engineering & Rapid Prototyping

Code(Credit) : ABC01(1-2-1)

Course Objectives

  • Understand concept of reverse engineering
  • Understand principles of imaging, cross-sectional scanning, digital data, computational graphics
  • Understand legality of reverse engineering concept

Learning Outcomes

  • Use the Digitized Shape Editor (DSE) workbench
  • Import and process the digitized data (scans or clouds of points),
  • Quick Surface Reconstruction (QSR) from the digitized data.
  • Create a mesh and extract characteristic curves to create surfaces using point cloud data

Course Syllabus

Module I: Introduction to Reverse Engineering                                                               2 (hrs)

Historical Background & Industrial Evolution,Reverse Engineering in Modern Industries, Motivation and Challenge, Analysis and Verification, Applications of Reverse Engineering & 3D scanning.

Practice :1       Generate a Model from a Product

 Module II: Processing the Point data & Creating Tessellated Mesh                                                 2 (hrs)

Stages in the Process, Introduction to Digitized shape editor, Importing the Point data, editing the cloud, Creating & Correcting the mesh, editing the mesh, creating tessellated mesh

Practice:2  Cloud Point Generation

Practice :3   Mesh Generation from Cloud Point data

Module III: Curve Creation & Processing                                                              2 (hrs)

Stages in the Process, creating and editing scans, creating curves, Additional tools, Introduction to quick surface reconstruction, creating scans by segmentation, processing curves

Practice : 4    Curve Generation

Module IV: Creating Surface                                                                                                 2 (hrs)

Stages in the Process, creating surface, using automatic processes, checking deviations

Practice :5   Surface Generation & Optimization

Module V : Additive Manufacturing                                                                              2 (hrs)

Additive Manufacturing Technology in product development-Materials for Additive Manufacturing Technology,Classification – Stereo lithography Apparatus (SLA)- Principle, process, advantages –Fused Deposition Modeling – Principle, process, advantages.Selective Laser Sintering – Principle, Process, advantages, Three Dimensional Printing – Principle, process, advantages - Laser Engineered Net Shaping (LENS)

Module VI : Delmia Additive Part Preparation Essentials

Preparing Infrastructure, Preparing Parts, Managing Rules, Generating the Slicing Path,

Practice : 6  Prepare a part for 3D Printing

Module VII: Master Project                                                                                                  2 (hrs)

Reverse Engineering of the Car Fender and 3D Printing


Text Books /Reference Books/Materials

  1. Dassault Systemes Companion Learning Space : Catia Reverse Engineering Essentials

Session Plan

Session 1

Introduction to Reverse Engineering


3D Scanning                                           

Session -3

Practice Session on Reverse Engineering a component

Session 4

Importing Cloud of Points                                  

Merging Clouds

Editing the Cloud

Session -5

Practice Session on Generating Cloud Point Data using 3D Experience

Session 6

Practice Session on Generating cloud point data using CMM & 3D Scanning

Session -7

Creating and Correcting Mesh

Editing the Mesh                                                   

Session 8

Practice Session on Mesh Generation and Optimization

Session -9

Creating and Editing Scans                                            

Session -10

Creating Curves

Additional tools - Offset, Rough offset

Session -11

Quick Surface Re-construction           

Session -12

Creating Scans by Segmentation

Session -13

Creating Sketches from Scans

Session -14

Splitting curves

Session -15

Adjusting Nodes

Session -16

Cleaning & Splitting Contours

Session -17

Creating Free form Surfaces

Session -18

Creating Surface on Network                                     

Session -19

Concept of Additive Manufacturing

Session -20

Additive Manufacturing Technology in product development

Session -21

Materials for Additive Manufacturing Technology

Session -22

Stereo lithography Apparatus (SLA)- Principle, process, advantages

Session -23

Fused Deposition Modeling – Principle, process, advantages

Session -24

Selective Laser Sintering – Principle, Process, advantages

Session -25

Three Dimensional Printing – Principle, process, advantages

Session -26

Laser Engineered Net Shaping (LENS)

Session -27

Introduction to Delmia Additive Part Preparation Essentials

Session -28

Preparing the Infrastructure using 3D Experience

Session -29

Practice : Infrastructure Setup for Additive Manufacturing

Session -30

Preparing Parts for Additive Manufacturing

Session -31

Practice : Parts for 3D Printing

Session- 32

Managing Rules

Session -33

Practice : Creating  Rules in 3D Experience

Session -34

Generating Slicing Path

Session -35

Practice : Generate Slicing and Exporting Output

Session -36      (5 Hours)

Master Project : Reverse Engineering a Car Fender

  • Import input data
  • Analyze and Correct the Mesh
  • Create Curves
  • Create Surfaces
  • Check the Quality

Session -37     (5 Hours)

Master Project : 3D Printing a Car Fender

  • Prepare the Infrastructure
  • Create Part
  • Assign Rule
  • Slicing & Output
  • 3D Printing

Case Studies

Case Studies

Our Main Teachers

Associate Professor, Mechanical Engineering                                                                                                        […]