Reverse engineering generates a CAD surface model that precisely represents a scanned object. Reverse engineering is used everywhere where work is performed manually on real objects and a CAD model is required for the subsequent process.
In model and mold manufacturing, design objects and vehicles modeled in clay are scanned and transferred to CAD surfaces.
In die manufacturing, manual changes to sheet-metal dies in the tryout phase are scanned The existing CAD model is updated based on the scanned data. CAD surfaces often have to be created for dies for which no CAD data at all are available.
In cooperation with the BWW Group, we have continually reduced the time required for design surfaces in recent years
Today, high-quality CAD design surfaces for a vehicle outer skin can be generated in less than 50 hours.
In the same CAD file, the Tebis designer analyzes and optimizes the quality of the digitized data and then creates a wire-frame model and then the surface model is created based on that. Using the practical curve and surface functions, the designer supplements the surfaces generated by reverse engineering Free-form surfaces can be quickly generated using Tebis surface technology – and in class-A quality.
These are the steps for using reverse engineering to generate high-quality CAD surfaces:
Using the semi-automatic and interactive drawing functions, users create an intelligent wire-frame model based on the scanned object (mesh model), on which the degree and segmentation of the surfaces and the quality of the surface transitions are automatically controlled. Using the wire-frame model, the user can define the layout of the surfaces and the qualities of the transitions to the adjacent surfaces. Tebis automatically calculates the surface model from the wire-frame model and the meshes. Using tolerance values, the user determines how tightly the wire-frame model and surfaces "adhere" to the digitized data.
High-quality design surfaces require first-class CAD surface quality, especially for defined characteristic lines. Tebis enables precise control of the transition areas between two main surfaces or connecting surfaces (natural or trimmed surfaces), in addition to the basic surface approximation settings. The user specifies an area around the edge where the surface approximates the boundary curve rather than the scan data. The change in the CAD surface is immediately visible in Tebis. The affected area can be easily adjusted until the optimal surface quality is achieved.
Tebis reverse engineering quickly generates virtual twins of real forming and injection molding dies. Existing CAD data can also be considered. In the following cases, reverse engineering is an extremely useful tool that yields significant time savings:
Die makers manually change dies in the tryout phase. This causes the CAD model to lose its validity. With reverse engineering, manual changes are scanned and conveniently imported into the CAD model file. This yields tremendous time savings for further optimization of the die and for duplicates.
Mesh data from the drawing simulation can also be used as the basis for reverse engineering. First, the curvatures of the draw die system are analyzed. The designer then generates the surface layout and fills the individual areas with four-cornered surfaces and n-cornered surfaces trimmed as desired. Your method planners can very quickly obtain surface models in this way.
CAD surfaces are the starting point for all design and manufacturing processes after model making. If the form is developed by manual design methods like clay models or if the items are parts for antiques or art objects, the CAD world must simulate reality as precisely as possible.
Model makers use reverse engineering to combine manual work and design technology and benefit from both worlds. You can create CAD surfaces for your physical models with very little effort. Learn more about the technical developments in cooperation with BMW Group Design. Reliable methods have been developed to combine form-finding via manual design as effectively as possible with virtual design.
The new process enables exactly the same dies to be quickly and efficiently fabricated and tried out for multiple locations at the same time. Our die manufacturers worldwide have benefited from this process. It allowed us to very quickly produce the dies for Mexico in a standardized process.
Tebis enables a very simple and fast realization of reasonable extension designs to the scanned mesh data. It is a unique advantage that in Tebis you can combine meshes and surface elements extremely well and then mill them all at once using the CAM modules.