Reverse Engineering

Dayton T. Brown, Inc. has the tools and experience necessary to provide reverse engineering services for many different components, parts, and assemblies. Whether for a dated or obsolete part without a technical data package (TDP) or for a proprietary component that is needed by our military, DTB can help.

We have had success following a multi-phased process to complete your reverse engineering programs. The process begins with data collection, inspection, and dimensional analysis – typically using a laser scanner that converts the physical object into a 3D model. This 3D model provides a baseline that is then optimized into a full parametric model. After material analysis is conducted to determine the component material and construction details of the underlying part, the model is finalized, and a TDP is produced.

For over two decades, DTB has provided 3D reverse engineering and prototype development services for various US government agencies, commercial enterprises, and military projects.

Reverse Engineering Services


img-description img-description Materials & Processes

Materials & Processes

Reverse engineering programs are undertaken as a team effort, including our metallurgical laboratory and our design engineering staff.

We analyze every metallurgical characteristic to determine alloy selection; manufacturing processes, such as forging, casting, and thermo-mechanical sequences; joining methods; surface finishes, such as plating and coating; and surface treatments, such as shot peening.

DTB also specifies the governing specifications and participates in developing technical data packages and vendor qualification.

img-description img-description Redesign Techniques

Redesign Techniques

DTB has the experience, skills, and equipment necessary to measure parts and/or assemblies and then reconstruct them as 3D models, and into 2D drawings, for fabrication. Our design engineers play a significant role in the reverse engineering process for military aircraft and helicopter structural, mechanical, and outside skin panel parts, such as aircraft fairings.

DTB routinely calculates geometric dimensions and tolerances (GD&T) and compares complex geometric surfaces and feature positions to nominal data to verify the object’s conformance to specification. We can compare part measurements of an object to the CAD model in order to determine real-time deviations from the design – saving time and expense for our customers.

We also perform 3D reverse engineering by digitizing a part or object to create a fully surfaced 3D model prototype.

3D Laser Scanning Equipment:

  • Measurement range: 9 ft. (2.7 M)
  • Volumetric accuracy: ±0.041 mm (±0.0016 in.)
  • Single point repeatability: 0.029 mm (0.0011 in.)

Laser Line Probe:

  • Accuracy: ±0.035 mm (±0.0014 in.)
  • Repeatability: 35 μm, 2σ (0.0014 in.)
  • Effective scan width (near field): 53 mm (2.09 in.)
  • Points per line: 752 points/line
  • Scan rate: 60 frames/sec.; 60 frames/sec. x 752 points/line = 45,120 points/sec.

Vendor Qualification:

DTB can help you down-select from a group of potential vendors by conducting quality assurance site surveys with particular attention to calibration, inspection, asset tracking, and quality control. Preliminary manufacturing process sheets are reviewed, approved, and later compared to the process sheets used to manufacture. First article inspections, proof load, and fatigue testing and evaluations are typically part of DTB’s vendor qualification process.

img-description img-description Product Evaluation
& Improvement

Product Evaluation & Improvement

DTB can evaluate your current or outdated materials – testing product specifications to determine if they are compatible with current materials, manufacturing processes, and specifications. Our experienced staff of engineers and metallurgists will evaluate your requirements, recommend alternative processes and specifications, or develop new ones to meet your needs.

DTB’s engineered product improvements can distinguish your product from the competition by applying new materials technologies and manufacturing methods, as well as upgrading your current product designs.

Our experience, technical expertise, and innovation can help improve product reliability by evaluating historical product failures and data that was collected during accelerated life testing. We can use the results to recommend alternative materials and/or design and process improvements, regardless of the source.

DTB routinely provides production improvement solutions in order to achieve shorter time to market. We offer the following types of product evaluation programs: