Specialised Service

Reverse Engineering of Parts and Components

Capture complex parts. Rebuild accurate CAD. Validate for manufacture. Structured-light scanning of machine parts, gears, housings, castings and tooling, reconstructed into editable CAD and manufacturing-ready STEP, STL and drawings. Every model is checked back against the scan and reviewed under registered Pr Eng oversight.

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Sasol Eskom Impala Platinum Sibanye-Stillwater Afrimat Growthpoint Concor Stefanutti Stocks Zutari Infrastructure South Africa
In short

Reverse engineering turns a physical part into an editable CAD model. Delta Scan scans machine parts, gears, housings and castings with structured-light and LiDAR scanners, rebuilds the geometry as parametric CAD, checks the model against the scan with a deviation map, and delivers STEP, STL and drawings ready for CNC machining, casting or 3D printing.

Reverse engineering turns a physical part back into a digital model that can be modified, manufactured or archived. The need is the same across every workshop and plant: a pump impeller, gearbox housing or custom bracket fails on equipment whose manufacturer no longer exists, a casting arrives on site with no drawing behind it, or a part that works well needs to be replicated, lightened or made in a different material. In each case the starting point is the part in your hand, not a drawing.

Delta Scan reverse engineers parts and components as an engineering-led service, not a scanning-only one. Small and medium parts are captured on the bench with handheld structured-light scanning, which resolves fine detail that laser scanners built for buildings cannot. Larger assemblies are scanned in place with LiDAR. The scan is rebuilt as clean parametric CAD, compared back to the scan as a deviation map, and delivered as manufacturing-ready files for CNC machining, casting, fabrication and 3D printing. Where a part is damaged or worn, the model is corrected to the design intent rather than copying the damage.

Selected output

Capture, reconstruct, validate.

A cast housing through the three stages: the structured-light scan, the rebuilt CAD and the deviation map that proves the two agree.

When to use it

Typical engagements.

The situations that usually bring this work to us. If one of them is yours, an engineer scopes it, not a salesperson.

Obsolete parts with no drawings

The manufacturer has closed or no longer supports the machine, and the only record of the part is the part itself. One good sample, or a worn one, is enough to rebuild a clean CAD model for re-manufacture.

Damaged or worn parts that must be replaced

A cracked casting, a worn gear or a broken bracket needs replacing faster than a supplier can deliver. The scan captures what remains, the model restores the original geometry, and the files go straight to a machinist or foundry.

Parts to replicate or 3D print

A clean, watertight STL from the scan lets you print a replacement, a pattern or a fit-check piece. Mesh density and surface finish are tuned to the printer and the job, with parametric CAD alongside if the design will change.

Undocumented spares on inherited equipment

Acquired plant often arrives with no surviving documentation. We build a digital library of the critical components, so the next failure is a file sent to a supplier rather than a search for a drawing.

Redesign and improvement

The part needs to be stiffer, lighter, made in another material or adapted to a new application. The scan gives the true starting geometry; the parametric model gives you something an engineer can edit.

Dimensional checks on new parts

A machined or cast part is scanned and compared with its CAD to confirm it is within tolerance before it is fitted, with a colour deviation map and a dimensional report rather than a handful of caliper readings.

How it works

Our process.

A repeatable five-stage workflow. The same disciplined sequence runs whether the site is a 500-hectare mining operation or a single 60-metre bridge.

01

Part assessment and scoping

We confirm the size, material and surface of the part, the accuracy the job needs, and the intended manufacturing route, whether CNC, casting, fabrication or 3D printing. Parts are couriered to our Johannesburg workshop or scanned on site when they cannot be moved.

02

Structured-light scanning

The part is scanned on the bench with a handheld structured-light scanner. Reference markers and a turntable give full coverage of complex geometry in a few poses. Shiny or dark surfaces get a removable matting spray so the scanner sees true geometry rather than reflections.

03

Mesh processing

The raw scan is cleaned, aligned and merged into a watertight mesh. Noise is filtered and holes closed to the fidelity the downstream use needs. For 3D printing this mesh, exported as STL, is already a deliverable.

04

Parametric CAD reconstruction

The mesh is rebuilt as editable parametric CAD. Cylinders, planes, fillets, holes, bolt patterns and threads are reconstructed as features with their design intent, not traced as a frozen surface. Damage and wear are corrected back to the nominal geometry. Dimensioned 2D drawings are produced where the manufacturing route needs them.

05

Deviation analysis and delivery

The CAD model is compared back to the scan. A colour deviation map and a dimensional report show exactly how closely the model matches the physical part, and the Pr Eng reviews the result before release. STEP, IGES, STL, native CAD and drawings are issued through DeltaCloud and archived for the next order.

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Equipment

What we use.

Calibrated, sector-matched hardware combined with proprietary software. The capture stack is selected for the asset, not the other way around.

Handheld structured-light scanner

Blue-light structured-light capture for small and medium parts, resolving fine features that site laser scanners cannot. Reference markers and a turntable for full coverage of complex geometry.

XGRIDS Lixel L2 handheld LiDAR

XGRIDS Lixel L2 handheld LiDAR

Larger assemblies and equipment scanned in place when a part cannot be removed or shipped.

Parametric CAD and deviation analysis

Features rebuilt as editable primitives, then compared back to the scan as a colour deviation map before anything is released for manufacture.

Sectors

Where this fits.

The same engineering discipline applies across Mining and heavy industry, Manufacturing and remanufacturing, Automotive and motorsport, Power, water and process plant. The detail changes with the asset class and the operational context.

Mining and heavy industry

Obsolete pump, gearbox and conveyor parts, mill and crusher components, custom brackets, fixtures and wear parts

Manufacturing and remanufacturing

Casting patterns, replacement part production, tooling, jigs and dies, design-for-manufacture improvements

Automotive and motorsport

Classic vehicle restoration parts, motorsport components, prototype iteration on housings, fittings and brackets

Power, water and process plant

Valve bodies, impellers, pump and turbine components, and ancillary parts where the original drawings are lost

FAQ

Frequent questions.

Direct answers to the questions clients ask most often before engaging.

What size of part can you reverse engineer?

Structured-light scanning on the bench suits parts from small machined components up to housings and assemblies around a metre across. Larger equipment is scanned in place with handheld LiDAR. If a part cannot be moved, we come to it.

What accuracy can you achieve?

The achieved accuracy is stated in the report for every part rather than quoted as a blanket figure. Structured-light capture on small parts resolves features well below a tenth of a millimetre, and the deviation map shows how closely the final CAD matches the scan.

What file formats do you deliver?

STEP and IGES for CAD and CAM, STL for 3D printing, native parametric CAD files, dimensioned 2D drawings where needed, and the point cloud or mesh on request. Formats are confirmed at scoping.

Is the CAD model editable, or a frozen surface mesh?

Editable parametric. Each feature, such as a cylinder, plane, fillet, hole or thread, is rebuilt as a feature an engineer can modify and dimension. An STL mesh is supplied alongside for printing or visualisation.

Can you scan shiny, black or very small parts?

Yes. Reflective and dark surfaces are given a removable matting spray before scanning. Small parts and fine features are captured with reference markers and multiple poses so no face is missed.

What about internal cavities I cannot see?

External scanning cannot see inside an enclosed cavity. Internal geometry is modelled from design intent, from a sectioned sample where one exists, or from the mating parts, and any assumption is stated in the report rather than hidden.

Do you manufacture or 3D print the part?

No. We deliver the files and the dimensional report; your machinist, foundry or print bureau makes the part. We will talk to them about tolerances and mesh settings so the file arrives ready to use.

How long does a typical part take?

A single small or medium part is typically returned within a week of receipt. Assemblies with multiple components are quoted per scope. Urgent production-down work is prioritised.

Do you keep the model for future orders?

Yes. Every reverse-engineered part is archived in your DeltaCloud workspace with version control, so a critical-spares library builds up over time and the next replacement is a file, not a project.

Related services

If this fits, these often do too.

Engineering programmes rarely run on a single service. These adjacent capabilities most often pair with the work above.

Accuracy & standards

Built to be signed, not just shared.

Pr EngECSA 202001436

Every engineering deliverable is reviewed and signed by Darryl Epstein, a registered Professional Engineer (Pr Eng, ECSA 202001436).

SAGIsurvey

Geospatial deliverables carry registered land-surveyor sign-off where accuracy must be certified.

Classstated

Every deliverable carries a stated survey accuracy class or BIM level of development (LOD), reported per engagement against check-point analysis.

Standardscited

Findings cross-referenced to the applicable codes (SANS, TMH, EN), with accuracy statements on every report.

Start here

Request a reverse engineering quote

Send the brief and our engineering team will review your enquiry and reply within one business day. Prefer to talk first? Call or WhatsApp us below.

Response within 1 business day · Pr Eng or SAGI signed

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