Project title

Reverse Engineering- Scanning & Design for Manufacture /Analysis

Abstract
Investigation of Reverse Engineering process for complex surface design (helmet
design)
A short lead-time in product development is strongly demanded to satisfy needs,
resulting from the globalization of manufacturing activities and the changes in market
requirements. The primary aim of this research study is to investigate how digital
reverse engineering and prototyping can reduce product design cycle time, and
simulate digital prototype tests of helmets before manufacturing. The investigation
will explore the relationship between aesthetic design features and mechanical
design features that support the safety. The research work will consider health and
safety, human factors, material properties research in terms of sustainability
Introduction
If engineering is defined into two types it can be defined as forward and reverse
engineering.
The traditional approach to engineering is forward engineering. This entails taking
technical data such as drawings, material information and relevant standards to
design a component create a computer model and export it for manufacture.
Reverse engineering is the process of taking a pre-existing design or product and
creating a computer model and relevant document directly from the pre-existing
example.
Firms specialising in reverse engineering carry it out for a number of reasons the
most common according to 3D scanners uk is that the original Cad data for the
original part no longer exits1 further reasons for the need of reverse engineering:
1. A replacement part that is no longer manufactured
2. Provide a suitable attentive to OEM spares when demand inflates costs and
waiting lists.
3. Analyse a competitive product and understand its superior and flawed
characteristics.
4. Aid the development of products in competitive market conditions.
In many engineering design situations the designers use prototyping to analysis
there designs. The use of physical models made from clay, plaster, wood and foam
rubber. These models are used to analysis the aerodynamics of systems common in
the automotive industry. Physical modelling is still widely used when designing in
CAD is to challenging or not possible. Reverse engineering offers a solution to this
as the finished component is the source of information for the CAD model. 3D
1 (3D Scanners Uk, 2012)

scanning technology can capture a product in digital 3D and the information remodel
in a CAD package and exported for manufacture or for computer Finite element
analysis to aid the products development.
The main focus of the research study is to investigate how digital reverse
engineering and prototyping can reduce the product design cycle time. By applying
the methods of reverse engineering to reverse engineer a bicycle helmet, the study
will aim to fulfil the following objective:
Create a digital computer model of a off the self helmet using appropriate
techniques.
Simulate digital prototype tests of the helmet and compare the results with ones
carried out on bought in example.
Explore the relationship between aesthetic and mechanical design features that
support safety.
Study the material properties that support safety and sustainability.
Explore the human factors (ergonomics) that govern helmet design.