Reverse Engineering: Technology of Reinvention

During the past decade reverse engineering has become a common and acceptable practice utilized by many original equipment manufacturers and suppliers. This course focuses on the application of modern technologies used to decode the design details and manufacturing processes of an existing part in the absence of the original design data. It emphasizes the real-life practice of reverse engineering in the aerospace industry from both scientific and legal points of view. Attendees will learn the applicability and limitations of reverse engineering through case studies and hands-on exercises.

Various measurement instruments, ranging from traditional micrometers to computer-aided laser probes, will be compared for their merits and shortcomings. The statistics of dimensional measurements and the acceptable tolerance of variations, with emphasis on industrial standards in real-life practice will be discussed. Material identification, manufacturing process verification and the system compatibility of the subject part to be reverse engineered will be covered in substantial detail. In addition, the materials specifications will be exemplified as useful supporting documents for substantiation data.

Note: Participants should bring a calculator for in-class exercises.

What Will You Learn

By attending this seminar, you will be able to:
  • Define the critical elements of reverse engineering
  • List the measurements and analyses required to duplicate/reproduce an OEM part by reverse engineering
  • Recognize if an OEM part can be duplicated/reproduced by reverse engineering
  • Judge if a "duplicated" part will meet the design functionality of the OEM part
  • Evaluate the feasibility of a reverse engineering proposal/project
  • Describe and implement a process to duplicate/reproduce a part by reverse engineering

Is This Course For You

This seminar is designed to assist individuals in various industries including, but not limited to, automotive, aerospace, off-highway, motorsports and parts brokerage firms. Corporate senior executives, engineering managers, engineers, technicians, government inspectors, sales managers, salespersons, lawyers and legal counselors will find the course relevant and informative.

Materials Provided

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Course Requirements

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  • Introduction
    • Historical background
    • Reverse engineering vs. machine design
    • Three basic requirements: form, fit and function
  • Geometrical Form
    • Dimensional measurement
    • Precision instruments of measurement
    • Tolerance
    • Virtual exercise of geometrical modeling
  • Material and Process Identification
    • Chemical composition identification
    • Manufacturing process verification
    • Materials specification substantiation
    • Machining process identification
  • Data Process and Analysis
    • Statistical analysis
    • Statistical exercise
    • Case study of statistical confidence
    • Reliability
  • Demonstration and Exercise
    • Demonstration of scanning
    • Hands-on exercise of reverse engineering
    • Case study
  • Regulations and Certifications
    • Government regulations
    • Industrial standards
    • Certification requirements
  • Fit and Function
    • System compatibility
    • Critical performance
    • Vendor substantiation
    • Safety and damage tolerance
  • Acceptance and Legality
    • Evolving industry trends
    • Moral and legal issues
    • Examples - legal precedents