Machine Reverse Engineering
When the part you need no longer exists in a catalog, Schimmel Engineering scans what you have — or what's left of it — and builds a production-ready CAD model from the ground up. Using a Creaform HandyScan Black Elite and SolidWorks, we take any physical part from the real world into a fully parametric model ready for CNC machining, casting, or additive manufacturing.
If It's Discontinued, NLA, or One of a Kind — We Can Reproduce It.
Most reverse engineering services give you a mesh file — a digital photograph of the part. That's not enough to manufacture from. Schimmel Engineering goes further: we extract the original designer's intent from the scan data, rebuild the geometry as a fully parametric SolidWorks model, and produce manufacturing drawings with proper GD&T callouts ready for a machinist or foundry.
We've taken this workflow from a single mail-in part through to countless machined, welded, and printed one-off, low-volume, and mid-volume production runs — each part fully interchangeable with the original. We handle the entire chain: scan, model, prototype, vendor selection, manufacturing documentation, and end-user assembly instructions.
If you have the part, we can scan it. If the part is degraded, warped, or missing entirely, we can often reconstruct it from the cavity, chassis, or mating surfaces it was designed to fit.
How Does the Scan-to-CAD Reverse Engineering Workflow Work?
Every reverse engineering project follows a structured process that turns physical hardware into production-ready engineering data.
Part Capture
We scan your part using the Creaform HandyScan Black Elite at ±0.0009 in. accuracy — capturing every surface, bore, and feature in a high-density point cloud. Mail-in or on-site. No surface preparation or damage to your original part.
Feature Extraction
Using Creaform OS 2.2, we extract critical geometry from the scan: bore centers, parting lines, wall thickness, draft angles, and mating surfaces. This is where we get inside the original designer's head — not just copying the shape, but understanding the intent behind it. When wear or damage has distorted the original geometry, this step identifies the underlying design intent and corrects for it rather than reproducing the failure, so the replacement part outlasts the one it's replacing.
Parametric CAD Modeling
All mechanical design takes place in SolidWorks. The result is a fully editable, parametric model — not a mesh or dumb solid. Features are properly defined, dimensioned, and ready for modification. Assemblies include fit checks against mating components.
Manufacturing Drawings & GD&T
We produce complete 2D drawing packages with GD&T callouts, tolerances, surface finish specifications, and material callouts. Drawings are formatted for domestic or overseas machining vendors and include all stack-up tolerance analysis required for reliable assembly.
Prototype & Inspection
Before committing to production, we typically run prototypes produced through 3D printing for fit and function verification, and use the HandyScan to perform dimensional inspection of first-article machined parts against the CAD model — catching vendor deviations before they become costly problems.
Production & Documentation
We manage domestic and overseas vendor relationships, coordinate manufacturing runs, and produce complete end-user documentation — assembly instructions, exploded views, and part lists. From file to finished product on your shelf, or your customer's door.
From Physical Part to Manufacturing-Ready File
These three tiers aren't a fixed pipeline every project has to complete — they're samples of where a project can stop. Some jobs only need a mesh file, for reality capture documentation or handoff to an outside solid modeling team. Others need the full parametric rebuild — solid modeling all the way to a native STEP or IGES file — and nothing more. Some go further still: manufacturing drawings generated directly from that STEP file, with GD&T callouts ready for a machinist. Below are three examples, one for each tier: a mesh scan of an Austin Mini, a parametric rebuild of a V50 engine case, and a manufacturing drawing generated from that same STEP file. Download a free sample mesh and STEP solid to inspect the files yourself.
Austin Mini — Mesh
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Output Type
Mesh File
V50 — Parametric CAD
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Output Type
Parametric CAD
Output Type
Manufacturing Ready
What Can Machine Reverse Engineering Be Used For?
Schimmel Engineering has applied this workflow across automotive, powersports, industrial, theatrical, themed entertainment, and custom fabrication applications.
NLA & Discontinued Part Reproduction
When a part goes out of production, the only option is reproduction. We scan originals — even worn or degraded ones — extract the design intent, and produce manufacturing-ready files for any quantity from one to thousands. Materials range from billet aluminum to nylon to stainless steel.
Engine Case & Drivetrain Components
We scan the original cast case, rebuild it as a billet-optimized design in SolidWorks, and manage the production run — from a single prototype to a full manufacturing batch. The same workflow applies to transmission cases, gearboxes, motor mounts, and bell housings. See the Puch ZA70 case study below for a real production run.
Automotive Interior & Body Components
Scan-to-manufacture for interior panels, package shelves, brackets, and body components where the original no longer exists in usable condition. We scan the chassis or cavity, build the replacement geometry, and produce cutting files for CNC routing, vacuum forming, or fabrication.
Custom Repair Kits & Replacement Hardware
When a repair calls for more than just a replacement part, we design the complete system — part, and any custom installation tooling it needs. See our BMW E30 window latch rebuild kit below, now available in our Products store. View Products →
Industrial & Machine Components
Reverse engineer worn or obsolete tooling, fixtures, jigs, and machine components. We produce parametric models suitable for redesign and improvement — not just copying the original flaw, but extracting intent and optimizing for modern manufacturing methods and materials.
Concept to Shelf — Product Development
Beyond reproduction, we handle complete product development: clean-sheet design, SolidWorks modeling, DFM review, vendor sourcing, packaging design, and customer documentation. If you have an idea for a product the market is missing, we can take it from concept to a finished product ready for sale.
Real Reverse Engineering Projects from the Schimmel Engineering Portfolio
Every project below was completed by Schimmel Engineering — real parts, real clients, real production.
Billet Engine Case · Powersports
Billet Puch ZA70 Engine Case — Scan to Production Run of 25
Fully laser scanned, parametric rebuild, and billet redesign of a vintage two-stroke engine case. 25 units produced in 2024 (~$30k run). Complete end-user assembly documentation included.
View Project →
Automotive · Concept to Product
BMW E30 Window Latch Rebuild Kit — Design Intent Reconstruction
Concept-to-product development of an anodized billet replacement latch kit with custom disposable installation tooling. Now available on Amazon with Prime shipping.
View Project →
NLA Part Reproduction · Powersports
Snorunner NLA Part Reproduction — Scan to MJF Nylon
Mail-in scan of an NLA vintage part, cleaned mesh, and MJF print-ready file — delivered for $250. The most cost-effective entry point for part reproduction.
Read the Case Study →
Mechanical RE · Powersports
CVT Contra Spring — Mirror-Wind Reverse Engineering
Mirror-wound CVT contra spring scanned, drawn, and sourced to production. 45 days. First try.
Read the Case Study →
Industrial · Extrusion Equipment
Twin PVC Extruder Screw — Interpretive Geometry Restoration
Worn twin compounding screws scanned and geometry reconstructed to factory-new specification for overseas reproduction.
Read the Case Study →
Automotive · NLA Fabrication
Saab 96 V4 Package Shelf — Scanned Chassis, Cut First Try
No shelf exists. Scanned the chassis. Aberdeen Studio cut it. $390. First try.
Read the Case Study →
What Does a Machine Reverse Engineering Project Cost?
Pricing is transparent and scales with scope. Below are real project cost breakdowns from completed work.
Mail-In Scan File
Customer ships part in — their cost
1 hr scanning & basic cleanup — $195
Additional cleanup if needed — $80/hr
Return shipping with insurance — ~$20
From $195 + return shipping — watertight STL/OBJ
Parametric CAD Model
Mesh file (as above) — from $195
Solid model from mesh — $250–$500 per part
2D drawings for machining — $500–$1,000
First article inspection — $195/hr
Typical total — $500–$2,000+
Concept to Production
Full scan-to-model — as above
Prototype prints & fit verification — varies
Vendor sourcing & production management
Assembly documentation package
Quoted per project — contact us
Industries We Serve
Reverse engineering and scan-to-CAD applies across every sector where parts wear out, go out of production, or need to be reproduced without original drawings. See our industry-specific service guides below.
Industrial · Power Generation
Power Generation & Gas Turbines
Turbine blade profiles, hot section components, and outage documentation for power generation maintenance teams and overhaul shops.
See Service Guide →Industrial · Paper & Web Processing
Roll & Nip — Alignment, Inspection & RE
Calender roll geometry, nip geometry measurement, and roll grinding reference data for paper, film, and web processing equipment.
See Service Guide →Industrial · Process Equipment
Industrial Plant Managers & Engineers
Worn extrusion screws and barrels rebuilt to factory spec, mandrel reverse engineering, and process equipment documentation when no drawings exist.
See Service Guide →Industrial · Toolmaking
Toolmakers & Injection Mold Shops
Worn cavity and core reverse engineering, EDM electrode geometry, molded part shrinkage analysis, and mold transfer documentation.
See Service Guide →Industrial · Heavy Equipment
Heavy Equipment Refurbishers
Worn pin and bore reverse engineering, structural distortion assessment, custom attachment geometry, and fleet condition documentation.
See Service Guide →Industrial · Maintenance
Millwrights & Machine Overhaulers
Pre-teardown as-built documentation, rigging clearance verification, shaft and bore inspection, and maintenance planning geometry.
See Service Guide →Quality · Metrology
Quality Engineers & FAI
First article inspection, GD&T deviation maps, incoming vendor dimensional verification, and custom inspection fixture design.
See Service Guide →Automotive · Custom Fabrication
Custom Shops, Restomods & Fabricators
Engine bay geometry for swaps and header design, body scanning for wide body fabrication, frame capture, and discontinued part reproduction.
See Service Guide →Defense · Government
Defense Contractors
Legacy system component documentation, as-built inspection, and reverse engineering for defense hardware without drawings or with out-of-date documentation.
See Service Guide →Machine Reverse Engineering — Frequently Asked Questions
What is machine reverse engineering?
Machine reverse engineering is the process of digitally capturing an existing physical part using precision 3D scanning, then converting that data into a fully parametric CAD model for CNC machining, casting, or additive manufacturing. Schimmel Engineering uses the Creaform HandyScan Black Elite to capture parts at ±0.0009 inch accuracy and builds production-ready SolidWorks models from that data — not mesh files, but fully editable parametric geometry.
Can you reverse engineer a part that no longer exists in good condition?
Yes. When the original part is degraded, warped, or missing entirely, we can often reconstruct its geometry by scanning the surrounding chassis, cavity, or mating surfaces and working backwards. We've done this for vintage Saab body panels and obsolete powersports components where no usable original existed — scanning the opening the part was designed to fill rather than the part itself.
What manufacturing methods can you support after reverse engineering?
We deliver production-ready models and drawings for CNC billet machining, sheet metal fabrication, FDM, SLS, MJF, and DMLS additive manufacturing. We also manage vendor sourcing, domestic and overseas manufacturing contracts, and produce complete assembly and end-user documentation packages.
Do you offer mail-in scanning for reverse engineering?
Yes. Mail-in scanning is the most cost-effective way to get started. Ship your part to our Nashville, TN lab (37206) — at your cost — and we return it with your digital file package plus commercial return shipping with insurance. A watertight mesh file (STL/OBJ, suitable for 3D printing) starts at $195 + return shipping. A reverse engineered solid model — fully parametric SolidWorks geometry ready for CNC machining — starts at $250 + return shipping for a single part. We accept parts from anywhere in the United States and internationally.
Where do you provide reverse engineering services?
Our lab is based in Nashville, Tennessee, and we serve clients nationally and internationally. For on-site scanning of large equipment or assemblies, we travel with advance notice — our equipment is hand-carry portable. For individual parts, mail-in scanning eliminates travel cost entirely and is available to clients worldwide.
Nashville, TN — Mail Parts Directly to Our Lab.
Ship to zip code 37206. We scan, process, and return your part with commercial insurance. On-site visits available within 50 miles of Nashville starting at $390. We travel nationally and internationally with advance notice.
Have a Part That Needs to Be Reproduced?
Send us photos and a description. We'll tell you exactly what the path forward looks like — and what it will cost.