The COVID-19 pandemic has had a huge impact on industry right around the world, and the knock-on effects will continue to be felt for many months and even years. Illawarra-based engineering firm, Leussink, believes reverse engineering of scarce parts can play a role in helping with the shortfall.
In short, reverse engineering is the reproduction of a product or part that cannot be obtained by other means. It involves measuring an object and reconstructing it as a 3D model, then manufacturing the part. The process is primarily used for machinery parts, rather than the production of parts for mass assembly line manufacturing.
“Reverse engineering is the only option when OEM parts are no longer available, particularly for an aged piece of equipment,” says Leussink’s Managing Director Jason Leussink. “However, there is no reason why reverse engineering processes cannot be used for newer components. The process can be applied in many industries and applications.”
Reverse engineering can be undertaken using a variety of tools and technologies. Generally, the complexity of the part being reverse engineered will dictate the type of equipment and software used.
“The simplest reverse engineering process is manual measurement and data collection of a physical model’s dimensions,” says Jason. “In this process, hand tools such as micrometers, Vernier calipers, and gauges are used to capture the critical dimensions needed to generate a part drawing.
“A more sophisticated approach is to use a coordinate measuring machine (CMM) like the Tomelleri Space Arm distributed by Leussink in Australia & New Zealand. The CMM measures the geometry of physical objects by sensing discrete points on the surface of the object with a probe.”
The part or product is measured and the dimensions immediately digitised and transferred to a CAD system, where surfaces are developed and drawings are finalised. Besides reducing the risk of measurement errors, processing data electronically significantly reduces the time required for the overall reverse engineering effort.
“Reverse engineering is particularly applicable where there are machines that can run 24/7 for months on end, repeating the same process over and over again,” Jason explains. “This type of high use means parts and accessories are going to need to be replaced regularly, and in some cases major components as well. Given the potential life span of some machinery, by the time a major part is required, it may no longer be in production or may be too expensive to replace, or in the case of our current times may not be available to order in a reasonable time frame. The data gathering of the reverse engineering process can also take place on-site, which is a huge advantage for large equipment that cannot be moved easily.
Leussink’s team delivers reverse-engineered components through the use of scanning and datapoint collection metrology equipment. The data is imported directly into CAD software, where a Finite Element Analysis (FEA) can be conducted for optimal performance and lifecycle. Once Leussink has the FEA, engineers can make adjustments to the design to increase efficiency and add value to the project, before putting the component into production.
“Reverse engineering was not possible a few decades ago,” says Jason. “But with technological advancements, it has become feasible and economical.”