Reverse Engineering Service

Reverse Engineering

Using Geomagic Design X CAD Software combined with the FARO ScanArm we are able to take digital captures of an object and perform the following reverse engineering services:

–  Generate useful surface and solid 3D data to assist with the creation or update of CAD designs in systems like Solidworks, Catia, NX, AutoDesk, etc.

–  Real world example: Scan the bucket connection points on an OEM wheel loader to allow for the development of aftermarket implements in Solidworks.

–  Capture digital recreations of hand built prototypes or one-of-a-kind custom parts with precise measurements allowing for digital documentation.

–  Real world example: Scan a plastic injection mold to capture hand grinding and polishing that was done to the runner system to allow a second tool to be built identical to the first.

–  The capture of an exterior shape on an existing part or model that will be used in the design of a new mating part.

–  Real world example: Scan the exterior of an automotive glove box light switch and use that shape as a bounding box to design a new switch in that will still fit in the space allocated for the original switch design.


FARO ScanArm

Utilizing traditional contact-based part probing at accuracy of+/- .0016” or non-contact 3D laser scanning at +/- .0025”. This Portable Coordinate Measuring Machine (PCMM) can be taken to any job site for direct measurements within hours of receiving a call or email.

Examples of the Faro Arms capability:

–  Faro used as a 3D Laser Scanner

–  Faro used as a CMM probing system

–  Other Faro reverse engineering case studies


Other Scanning Technologies

While the Faro ScanArm is a great fit for most projects DE has access to other scanning technologies for the times when jobs necessitate something other then a red line laser scanner. These other technologies include:

–  Industrial CT scanning: CT is well suited for very small parts that are highly detailed or part that require the scanner to look inside them (plastic injection molded parts, assemblies, hollow parts, etc).

–  Blue Structured Light Scanning: Blue Light is useful for capturing large parts in extremely high detail as well as capturing color data while scanning.


Lab

DE has a onsite metrology lab that is temperature controlled and has the ability to accept large parts that require movement with a Hi-lo.


Send us your scan / probe data

DE has several customers who own their own 3D scanning systems but don’t want to deal with training and maintaining a reverse engineer on staff for occasional projects. DE steps into this situation to handle all of their reverse engineering needs. After scanning the part they send us the raw scan data files and have us handle the reverse engineering they need completed. This also saves them the cost of maintaining a seat of Design X.

3D Printing Service

DeWys Engineering is located in the same building as its sister company, Forerunner 3D printing. Due to this, DE is able to offer its customers not only engineering services and 3D laser scanning, but also 3D printed parts using SLA, FDM, SLS, CLIP and Metal Printing as well as Quick Cast investment casting patterns.

For more information on our 3D Printing capabilities, please click the link below:


F3DP offers in house SLA Printing in 2 materials:

Somos Watershed – A clear material with a slight blue tint. Watershed is an ABS-like material that can either be sanded extensively and cleared for things like lenses and light pipes or can be blasted with a water hone to a milk jug like opaque finish. This material is great for parts that require an inside view to check the fit and function of internal components or to look for water and dust intrusion into the assembly during testing.

Somos NeXt – A off white material with strong ABS like characteristics. NeXt is F3DP most popular material and the one we are most likely to steer customers to if they are unsure of what type of material they should use for their part. This material is also very well suited for model making and can be sanded, filled and painted with automotive quality colors and surface finishes by F3DP’s in house model making staff.


More information on the SLA 3D printing process:

F3DP runs 3D Systems SLA 5000’s these are incredibly versatile machines that have the ability to print in layers as thin as .004″ and produce features as small as .002″ when parts are properly oriented on the build platform. These machines also offer a large build platform of 20″ cubed to allow for large parts. In the event that a part is to big to fit on the machine we have the ability to split the part into sections, print each one individually, and then light weld them back together to form large parts.


Other 3D Printing Technologies Available from F3DP:

CAD Design Service

As a CAD Design Service provider for many different industries, DE’s Designers and Engineers maintain a wide set of skills and proficiency across many different CAD packages including:

Solidworks | CATIA V5 | AutoDesk Fusion | Autodesk Inventor | DraftSight | Geomagic Design X

2D Drawings:

Create 2D blueprints that are linked and updated with the 3D model as well as custom title blocks with smart properties.


 3D Modeling:

Capable of building equation based models that can be driven using Excel design tables. This allows anyone to build simple parts to aid with sales and quoting processes.


3D Assembly:

Combining hundreds of 3D components, we are able to create accurate, true-to-life representations of any project allowing us to perform structural tests like correct fit, clash, center of gravity and mass of an object all before a single part is manufactured.


Advanced 3D surfacing:

Create and manipulate 3D surfacing for a endless variety of simple to complex parts ranging from machine nesting to water sports products.


 Design for 3D Printing:

Designing parts for economical production as 3D printed plastic or metal components requires specialized knowledge and experience, due to DE’s close relationship with Forerunner 3D Printing, we are experts in this field.


 Sheet Metal Parts:

We design 3D sheet metal parts and assemblies, which can be unfolded into flat patterns and can be easily turned into 2D prints. These 2D prints come complete with bend lines and ready to laser cut .dxf blank files.


Weldment Parts:

We can create and design a full 3D representation of a weldment, detailed in blueprints. These blueprints will guide in the cutting, assembly, and welding of the part on the shop floor.


Photo Realistic Rendering:

Using the CAD data of your project, we are able to create marketing ready images to capture a complete perspective of your device. We are not just a CAD Design Service, we build our own website entirely with renders we produce from projects we have worked on!


Data Management:

We routinely deal with hundreds of assembly links, massive assembly trees, and complex filing systems. DE also has experience in data translation between tier-one-suppliers and OEMs.


 Plant Floor Layout:

AutoCAD allows for the creation of 2D plant blueprints which assist in renovations, expansions, or equipment layout.


 CAM Programming:

Experience in writing and posting out NC programs to HAAS & HURCO Equipment using Autodesk Fusion 360. As a CAD Design Service provider, we pride ourselves on maintaining our manufacturing roots, CAM programming was DE’s first line of business in 2010.


Basic FEA analysis:

This allows us to complete design performance tests on your parts to determine the best materials to make your part from given their purpose.


Your Remote Engineering Department:

As a CAD Design Service DE has built up a special talent for working with both clients local to West MI as well as other across the globe. Our staff work flexible hours to facilitate meetings in time slots that are convenient for our customers around the world. We also have a conference room built out with a full telepresence meeting system to allow our Designers and Engineers to easily interface with remote teams in an efficient and collaborative way.

Automated Equipment

DeWys Engineering has on staff design engineers with years of practical experience in the design of custom automated machine’s for industries ranging from automotive and aerospace to agricultural and forestry. Our process starts with sitting down with our clients (and in most cases their end customers) to determine the scope of the project and drill down to find the critical features or requirements that the automated system will need to have in order to be successfully integrated into existing processes on the shop floor.

In the event that this is a legacy or take over job for our customer and 3D CAD data on the part is not available. DE has the ability to handle the capture and reverse engineering of our customers part via our in house 3D Laser Scanning capabilities.

Next comes the concept design, DE researches possible solutions that meet the customers requirements and assembles a 3D concept of the machine in CAD that is then reviewed with the customer. After getting feedback the concept is adjusted and then fleshed out in a full design with motions study’s, operator ergonomics, cycle time evaluations, and purchased part vendor meetings . Upon one final review with the customer the design is approved and 2D Prints are completed. This design package is then released to the builder for them to begin manufacturing the custom automated machine.

DE’s involvement does not have to stop after the design is submitted to a builder. Many times we are kept on call to answer questions, handle print redlining, and trouble shoot issues during the build and eventual runoff of the automated system.  We also work closely with both in house and outside controls groups usually starting during the concept design phase to ensure that the proper sensor, electric motors, and other items traditionally handled by a controls group are included in the design and properly sized and accounted for on the final 2D prints and bill of materials (BOM).

In the event that you are an OEM who does not have a preferred custom automated machine builder DE has a wide network of excellent  partners in this space that we have had long term working relationships with and who would be happy to quote your project. Also, geography is not a barrier to this process, while located in West Michigan, DE has worked with clients all over North America to help bring their custom automated machine’s to life.


Some Examples of previous projects we have worked on:

 

Agricultural / Heavy Equipment

DeWys Engineering has helped multiple customers with both heavy equipment and farm equipment new machine design (including purchased part sourcing, R&D, project management, prototype production, and infield trials) as well as engineering updates to existing equipment. We bring our background in mechanical engineering, mechanism design, weldments, sheet metal, hydraulics, and controls integration to each new project in order to design equipment that meets or exceeds our customers design specifications.

Product Development

We have designed with many different materials (including plastics and silicone) as well as worked with electrical engineers to integrate electro-mechanical systems into products. We use the traditional approach of starting with industrial design sketches and working into a full 3D design with the end goal being a 3D printed prototype that is fully functional. Where we differ from other firms is our strong background in manufacturing. We don’t just design and engineer a product that will meet the customers end goal, we also design a product that is manufacturable in a cost effective manner with the least amount of upfront tooling and start up costs. DeWys Engineering can also manage the sourcing and project management of your manufacturing.

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Locally owned and operated from Coopersville Michigan.

Contact Us Today

616.604.1977 - info@dewyseng.com

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