Cam gear is a critical component of the timing system in an internal combustion engine, ensuring the synchronized opening of the engine valves, pistons, and rotating parts, but their unavailability may result in long-term downtime or expensive replacement. Reverse engineering (RE) systems also play an important role in promoting sustainable practices projects in automotive technologies. The study focuses on presenting a proposed method for redesigning damaged parts in engines using image processing technology by creating an-accurate CAD model. In addition to clarifying of the expected causes that led to cam gear damage. The proposed method involves taking a high-resolution image of the damaged part, then applying advanced image processing algorithms to analyze and reconstruct the geometry of the part. The data is then converted into a high-resolution 3D CAD model. This approach aims to address the challenges of replicating worn or broken parts, providing a cost-effective maintenance and replacement solution for operation. The main parameters taken into consideration when applying the proposed method include: material properties, dimensions, geometrical features and stress analysis, and deformation on the cam gear. The accuracy of the reconstructed CAD model is verified in two ways: (1) by comparing it to the original part specifications and (2) by functional testing in a dynamic simulation environment. Furthermore, the results showed that AISI 4340 material achieved the highest hardness (least deformation) in both shear and Von Mises. The design selection criteria in terms of maximum stress and total shear deformation were also met completely safely. The study confirmed that the proposed method is effective and reliable in redesigning damaged cam gears in automotive engines using image processing and 3D CAD modeling, which improves the life cycle of damaged components, reduces downtime, and promotes sustainable practices by extending the life of the engine body or similar objects. In addition, it can be used for continuous improvement of cam gear design. Where, inspection engineers can also improve the performance of automotive engine parts in terms of reliability and durability. In conclusion, this research studies an innovative unprecedented step by adding a new reverse engineering method, after verifying its practical applicability, with the aim of enabling decision makers and specialists to redesign engineering parts that are not available in the market.