Military/Aerospace

Reverse Engineering is a critical step in the process of manufacturing obsolete structural components that lack sufficient historical engineering data for exact reproduction. Direct Dimensions, Inc. has been providing Reverse Engineering (RE) services to the military and aerospace industries for the past decade. Our advanced scanning equipment, technical expertise, and 10-year experience enable us to provide a wide range of tailored solutions for any project.

Our advanced methods for capturing the complex surface geometry of legacy parts utilize laser scan technology to obtain accuracies to .001 inches. Raw point-cloud data is gathered, processed, and constructed into 3D models in many cases without direct physical contact which may potentially damage irreplaceable parts. From the 3D models, the mechanical components are reconstructed to their original design intent and measurements are validated for proper manufacturing. We then provide the client with a final model in a variety of any suitable CAD formats. In many cases, the results of our RE process is more comprehensive than the original documentation for the component.

Our proven process of Reverse Engineering can be generalized into the following steps:

• examine the part, understand requirements, develop RE strategy
  
• measure and laser scan the part, format and analyze the dimensional data
  
• generate CAD model using design intent methodology and tolerance analysis
  
• verify accuracy of model with comparison to the original part scan data

Direct Dimensions, Inc. can handle an extensive range of project input formats and provide the most efficient services to deliver a desired final product for end application. The table below outlines several variations:

Project Inputs:

Direct Dimensions Services:

Deliverables:

• Sample Parts
• Existing Documentation
• Tooling and Molds
• Manufacturing Requirements
• Quality Requirements

• Laser Scanning
• 3D Surface Modeling
• 3D Solid Modeling
• 2D Drawings
• Tolerance Analysis
• Project Management

• 3D CAD Models
• Tolerance Analysis
• Rapid Prototype Sample
• Other Engineering Data

Typical Project Case Study - Hand Control Stick

Direct Dimensions, Inc. was presented with a Reverse Engineering project to provide remanufacturing data for a complex hand control stick. In addition to high accuracy requirements, the project was also on an extremely tight schedule.

Below is an overview of the project showing the customer-supplied OEM components through our RE process to complete solid models. The complex geometry of the individual component parts was captured using both laser scanners and CMM digitizers. Raw data was processed into surface geometry and then used to generate solid CAD models for machining.

The project was completed on budget, ahead of schedule, and exceeding customer requirements for accuracy and quality.

Click here to view the Hand Control Stick Direct 3Dview Model

Reverse Engineering of Aircraft Fuselage Structure

About Direct Dimensions

Direct Dimensions, Inc. was established in 1995 and has since become a leader in the reverse engineering industry. Our extensive experience spans from small consumer parts to major industrial components. Industries include: automotive, medical products, sculpture, architecture, forensics, product development, cultural preservation, visualization & animation, and military/aerospace.

At Direct Dimensions, Inc, only the most current and exact technology is utilized. This includes our scanning equipment to our software programs. Direct Dimensions, Inc. consists of a staff of expertly trained and skilled individuals with the abilities to provide solutions to any project. Our experienced technical staff allows us to deliver the most efficient solutions while maintaining a solid relationship with our clients.

Direct Dimensions, Inc. is constantly updating our capabilities as they become available and we continue to develop industry standards in technology, methodology, and accuracy.

Contact Direct Dimensions, Inc. for More Information