Development of an integrated laser-based reverse engineering and machining system

Reverse engineering technology plays an important role in a variety of manufacturing applications. It significantly reduces the production lead time and the costs of the part duplication processes. This paper evaluates the feasibility of using reverse engineering and concurrent engineering methods with data obtained from state-of-the-art laser scanning to remanufacture complex geometrical parts. Two aircraft structural components were evaluated in this study: a forward latch fitting of a C 141 and a leading edge rib of an F-15. The first phase of this project, accuracy characterisation of a reverse engineering system, demonstrated that loser scanning and CAD model reconstruction can duplicate aircraft structural components accurately and efficiently, within a tolerance of :+/-0.127 mm (0.005 in). The second phase of this project, development of a concurrent engineering system, showed that an integrated reverse engineering and CAM machining system can make the entire remanufacturing process more automatic and efficient, further reducing part turnaround time.