The conventional approach to reverse engineering typically involves taking part measurements by hand using tools such as calipers, micrometers, height gauges, or gauge blocks. While these tools are effective for capturing basic dimensions, they fall short when it comes to accurately measuring complex or freeform geometry. When using traditional measurement tools, often-times printed templates or 2D drawings are used to visually verify measurements, which often requires constant iterations and adjustments, all done by hand. Overall, this traditional method can be time-consuming, labor-intensive, and frustrating.

Digitize Your Reverse Engineering Process with Scan to CAD Workflow

Step 1 Digitize Measurements with a 3D Scanner

A 3D scanner captures accurate measurement data by digitizing a physical object into a 3D model, which serves as a reference for creating a parametric CAD model. Having all the surface measurements at your disposal eliminates the need to start the design from scratch.

Step 2 Design Your Part in CAD Software

Import the output mesh data from a 3D scanner into your preferred CAD software with the help of a plugin (SOLIDWORKS, Rhino), or use a standalone reverse engineering software (Geomagic Design X, QUICKSURFACE) to guide the creation of a professional CAD model.

Using a handheld 3D scanner like the Artec Leo for car customization and repair makes a lot of sense. You can capture detailed 3D surface measurements quickly and easily with this portable device. Small enough to fit in the palm of your hand, you are not bound by wires or a computer while scanning. It delivers accurate, repeatable data you can rely on to make informed decisions. Scan the part or vehicle once, then move straight into design by reverse engineering directly into CAD using precise measurement data. You’ll gain greater confidence and control, allowing you to complete projects with improved accuracy—and deliver better products in less time.

An Artec customer demonstrates the benefits of using an Artec Leo for taking measurements firsthand.

“Initially, we spent 3-4 days going back and forth, templating, [3D] printing a test piece, changing it, printing another. Prints were made of cheap material as well–not the stuff I used for end parts–we replaced this process with just 15 minutes of scanning.”

Dom Tucci, Industrial Designer Artec Leo customer Tucci Hot Rods

Reverse Engineering using a 3D Scanner

No more taking measurements manually. 3D scanning digitizes the reverse engineering workflow.

Scan Data

CAD Creation

Scan (left image): Using a 3D scanner to take measurements of an entire car or car part.
CAD creation (right image): Once you have all the surface measurements of the part, you can use them as a direct reference (similar to tracing) when creating the new CAD model.

Source: Using 3D Scanning to Repair and Customize the Famous Ford GT40

Compared to traditional methods of taking measurements, 3D scanning is a powerful tool for data collection. 3D scanners digitize a physical object to create a digital twin (or 3D model) of highly complex, organic surfaces of any autobody or automotive parts. They are super fast at collecting surface information, capturing millions of measurement data points per second with sub-millimeter accuracy.

By replacing traditional 2D measurement tools like tape measures, calipers, and hand gauges with a 3D scanner, you can capture every measurement point with exact XYZ coordinates, making it easy to pinpoint its exact position in real-world 3D space. These measurement points can then be imported directly into CAD software, eliminating manual data translation and significantly streamlining the design process.

Comparing Physical and Digital Methods

Physical Method

The conventional way of taking measurements manually

• Labor-intensive solution.
• Yield inaccurate and unreliable measurement data for complex parts.
• Difficult to figure out relationships between features.
• Can only take key dimensions.
• Contact measurement solution.
• Frequent and costly iterations.

Digital Method

Using a handheld 3D scanner for taking measurements

• Efficient measurement solution: Capture millions of data points per second, with measurement data in digital format.
• Take measurement once: Once the object is scanned, you can recall any measurements at any time on your computer.
• Non-contact measurement: No measurement interference with the part.
• Accurate measurements: Avoid costly rework. Using Artec Leo as an example, it captures measurement data with an accuracy up to 0.1 mm with a resolution of 0.2 mm.
• Measurement data can be imported into CAD software for use.

Not All Measurements are Straightforward

Taking manual measurements using tape measures, rulers, or calipers is a time-consuming and tedious task—especially for complex shapes and contours like those found on a car. With full surface capture, a 3D scanner collects measurements of the entire shape and surface of the vehicle part, not just a few key dimensions like manual measurement methods, which increases the risk of missing critical areas or angles.

Now that we’ve discussed the benefits of using a 3D scanner for reverse engineering, let’s take a look at why the Artec Leo works so well for digitizing cars, trucks, and other vehicles—especially when compared to other 3D scanners in the market.

The Artec Leo has no problems 3D scanning the exterior and interior of the car, all thanks to its portability and compact body. There’s no need for a computer during the data capture stage. It’s a self-contained device.

Scan Data Captured Using a Handheld 3D Scanner

3D models captured using the Artec Leo. This handheld 3D scanner captures all surface measurements of the physical part.

Reason #1: Take the 3D Scanner Directly to the Part that Needs Scanning

Let’s face it—bringing certain cars into the shop isn’t always practical. Whether it’s a collector’s vehicle, a race car, or a fragile car part, sometimes it’s better to bring the scanner to where you need to scan.

If you think 3D scanning is complicated, take a look at this video. Art scanned a truck bed outdoors using the Artec Leo. This handheld 3D scanner can scan difficult surfaces—even shiny frames, hood, or dark surfaces.

True Mobile Freedom

One of the biggest limitations of traditional 3D scanning solutions is the setup. Wires, tripods, and bulky computers—they all add time and limit where you can work. Whether you’re working on a car in the shop, need to scan at a client’s location, or scanning outdoors at a parking lot, the Artec Leo adapts to your workflow—not the other way around. 100% portability means true mobile freedom.

Reason #2: 100% Wireless 3D Scanning

Artec Leo is a truly wireless professional 3D scanner. Gone are the days when you might trip on the wire or have to constantly look back and forth on a separate computer to make sure you are capturing good-quality data.

With Artec Leo as a self-contained device, that means:

• It fits in your hands and moves easily around any vehicle.
• No cables to trip over or manage during scanning.
• No need for a laptop or PC tethered to the scanner.
• Battery operated.
• 100% wireless scanning and data transfer with Wi-Fi connectivity.
• A built-in touchscreen display lets you see your scan in real-time, so you know immediately whether you’ve captured everything you need. You can confirm the data is captured correctly while scanning on-site before you head back to the office.
• No problems with 3D scanning indoor or outdoor.

With the freedom to work wherever you go, feel confident that you’re collecting clean, complete data every time.

Reason #3: It’s a Smart Device Powered by Machine Learning

Powered by HD Mode

Using intelligent algorithms to generate ultra-sharp, clean, and detail-rich scans.

Artec Leo is a smart device with onboard processing. This means it processes data as you scan, adds more scan data, and aligns them in the scanner without the computer during the capturing stage. Powered by proprietary intelligent algorithms in Artec Studio 3D scanning software, Artec Leo captures only the data you need–more intelligence for less processing time and cleanup work.

HD Mode

On Off

Measurement is the first part of the reverse engineering process. Creating the CAD is the more difficult part of the project, but it’s made easier with 3D scanning. The scan gives you the intel you need to confidently sketch your design in CAD.

Using the Scan to CAD Method of Reverse Engineering

Benefits:

• Speeds up your design time frame (streamlines the workflow)
• Reduces product development costs (saving you labor time)
• Gets you more accurate CAD models (develop better products)

Using manual measurements to create CAD models presents a lot of challenges. It’s tough to get accurate data from complex parts, especially when you’re dealing with organic and complex features. Figuring out clearances and making sure parts fit together properly is also tricky, since traditional measurement tools don’t give you the full picture. Mirroring parts accurately by hand is another headache. The whole process often turns into a frustrating cycle of trial and error just to get everything to fit right.

On the other hand, 3D scanning makes CAD creation much easier. It captures the full geometry of a part with a 3D scanner, with all the detail and accuracy you need. The best part? You can use the scan data directly in your CAD software as a reference—like tracing over a detailed outline—so building accurate models becomes a lot faster and less headaches. It cuts down on guesswork, reduces revisions, and helps you get to the final product faster and more smoothly.

Steps to CAD Creation

Physical Method

The conventional method of reverse engineering using hand measurements

Steps:

1. Take measurements by hand.
2. Design CAD from scratch using a few key dimensions.
3. Use 2D templates to make sure measurements taken are accurate. Repeat until you think it’s right. This usually involves many revision cycles.
4. Prototype.
5. Test to see if the prototype works. Repeat and refine until you get it right.
6. Done.

Roundabout Way

• Trial and Error: Revision cycle nightmare. Difficult to get fit and finish exactly right.
• Difficulty in measuring moderately to extremely complex parts accurately.
• Creation of properly mirrored parts is extremely difficult.
• Challenging to assess clearances accurately.
• Difficulty in making sure proper fitment and mating of assemblies and other components.

Digital Method

Using the Artec Leo handheld 3D scanner to take measurements digitally

Steps:

1. Measure once with a 3D scanner.
2. Design the part with visual reference guides of 3D surface data.
3. Most of the verification work is done digitally rather than physically. Adjustments can be made digitally.
4. Prototype (Fewer fixes and work compared to the physical method).
5. Done.

Straightforward Way

• Accurate measurements mean no guesswork. Creating a digital twin of a physical part allows you to have the measurements directly on the computer you can always reference.
• You don’t have to design from scratch. You can easily trace the scan data to assist in the creation of CAD.
• Produce better quality products.
• Guarantees proper fit and functionality of the designed part.
• Designing products faster means taking on more projects and doing more complicated work.

Case Study: Why Scan to CAD is a More Efficient Design Method

“Using the 3D mesh data to determine clearances and ensure the proper fit of mating parts becomes significantly easier and faster. As an extra advantage, the parts our team is designing are extremely accurate.”

Richard Schonberger Co-owner and CEO Philadelphia Racing Products

Philadelphia Racing Products (PRP), a manufacturer of high-performance aftermarket automotive parts, is dedicated to meeting the rigorous demands of racing enthusiasts. To keep up with growing customer demands, their engineering team was looking for an efficient solution for reverse engineering. In the past, they had to model the existing component first before they could even start designing the mating part—the product they ultimately needed to manufacture. With the adoption of a Scan to CAD approach to product design, the team can now reference a digital 3D mesh of the physical part instead of recreating it from scratch, allowing them to focus directly on designing the mating part. This has significantly streamlined the entire process.

Designing a Mating Part

Physical Method

The conventional way of taking measurements manually

Steps:

1. Model the physical part (time-consuming).
2. Then design the mating part from scratch in CAD software with a few key dimensions (time-consuming).
3. Done.

Digital Method

Using a handheld 3D scanner for taking measurements

Steps:

1. Model the mating part in CAD software using scan data as a guide (easier and faster than the physical method).
2. Done.

Example #1: Scan to CAD – Streamline the Product Design Process of Mating Parts

The PRP team used QUICKSURFACE for SOLIDWORKS to design a custom engine valve cover for a Chevrolet ‘Big Block’ motor in a hydroplane racing boat.

Example #2: Scan to CAD – Streamline the Product Design Process of Mating Parts

The PRP team used QUICKSURFACE for SOLIDWORKS to design a Billet LS Flexplate.

“Using Scan to CAD approach to product design, we see significant efficiency gains in our product design workflow. Drawing from my own experience, on average, the time required to design a part is now reduced down to approximately 25% of the original time or less.”

Chase Evans Lead Engineer Philadelphia Racing Products

Another key benefit of the Scan to CAD approach to design is the streamlined verification process. By digitizing the design process, the PRP team can now complete 90% of verification directly within the CAD model, eliminating the need for repeated checks against mating parts. This digital-first approach gives the team greater confidence going into the physical prototyping stage, knowing that fitment and clearances have been precisely validated.

If you’re a SOLIDWORKS or Rhino user, you can take advantage of a plugin like QUICKSURFACE for SOLIDWORKS to work seamlessly within your existing CAD environment. This native integration allows you to import 3D scan data directly into the software and convert it into editable CAD models. There’s no need to switch between multiple programs or learn a completely new software. QUICKSURFACE is intuitive to use and streamlines the reverse engineering workflow by taking advantage of 3D scanner data—saving time and improving accuracy right inside the tools you already know.

Adopting a Scan to CAD approach in product design can truly be a game changer. By capturing accurate 3D data from existing car components or autobody, designers and engineers can skip time-consuming manual measurements and never-ending iterations. This not only speeds up the development process but also improves accuracy, reduces errors, and allows for better design. Whether you’re customizing parts, reverse engineering, or restoring legacy equipment, integrating Scan to CAD into your workflow leads to smarter, faster, and more reliable results.

Book a Demo to See How 3D Scanning Can Help You with Your Automotive Application