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Reverse Engineering / Design for Manufacture, Product Revaluation


Contact DTB with your product design and improvement project. Our technologies can make your process more efficient.

Reverse Engineering

Complete Reverse Engineering Projects

facilitated by Portable CMM / Laser Scanning Measurement Services

DTB prides itself in performing high quality inspection and design work. Our exacting measurements and attention to detail result in engineered prototypes of higher value with more detail, improved durability and better performance.

DTB can reverse engineer and develop products.

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

CAD – Computer Aided Design

Design Engineering Services: CAD – Computer Aided Design

The design/engineering department’s primary Computer Aided Design (CAD) Software is the Inventor (3-D/2-D CAD Software) AutoDesk version 11 system.

The Inventor software is a solid model, three and two-dimensional design/drafting system.

Through the use of many CAD software translators (.DXF, .DWG, .PDF, .IGES and .STP), the design/engineering department is capable of interfacing with other CAD systems (i.e.: CATIA, Pro-E and UG/I-DEAS. )

The Inventor software is supported by three computer servers (one main drawing release, backup and archive system).

CAE- Computer Aided Engineering

Design Engineering Services: CAE- Computer Aided Engineering

Through DTB’s integrated computer network management and concurrent engineering system, it provides our engineering team with a seamless process between engineering design, analysis and manufacturing.

This provides a synergistic collaboration of engineering disciplines to be efficient and expedient with every engineering program.

This has proven to lower DTB’s product development costs and has greatly shortened our design cycle process.

Typical processes in a CAE design cycle are:

  • Stress analysis on components and assemblies using FEA (Finite Element Analysis)
  • Thermal and fluid flow analysis Computational fluid dynamics (CFD)
  • Kinematics
  • Mechanical event simulation (MES)
  • Analysis tools for process simulation for operations such as casting, molding, and die press forming
  • Optimization of the product or process

Design engineering services are an integral part of our core business. Engineering design focuses on in-house product development and test facilities design while the services we provide are focused on satisfying our customers’ needs.

These design engineering services include: product development support, product conformance inspection, reverse/re-engineering, service life extension determination, and product improvement.

Our design engineering staff has the skill to design and develop new products to meet a customer’s needs as well as designing test facilities and test fixtures to facilitate customer product testing in the environment it was intended to operate in.

reverse-engineer-tailpipe 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 compare 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. Parts and Assemblies Redesign DTB has the capabilities, skills and equipment to measure parts and/or assemblies and then reconstruct them as a 3D models and into 2D drawings for fabrication. Our engineering design department plays a large role in the reverse engineering of military aircraft and helicopter structural, mechanical and outside skin panel undocumented parts (ie: aircraft fairings).DTB routinely:

  • Calculates geometric, dimensions and tolerances (GD and T) measurements and compares complex geometric surfaces, and feature positions to nominal data to verify your object’s conformance to specification.
  • Compares part measurements of an object to the CAD model to determine real-time deviations from the design, saving cost and time for our customer
  • Performs 3D Reverse Engineering by digitizing a part or object to create a fully surfaced 3D model-prototype.

Our 3D Laser Scanning Equipment Performance Specifications:

  • Measurement Range: 9 ft. (2.7m)
  • Volumetric Accuracy: ±.041 mm (±.0016 in.)
  • Single Point Repeatability: .029 mm (.0011 in.)

Laser Line Probe:

  • Accuracy: ±.035mm (±.0014 in.)
  • Repeatability: 35μm, 2σ (.0014 in.)
  • Effective Scan Width: Near Field 53 mm (2.09 in.)
  • Points per Line: 752 points/line
  • Scan Rate: 60 frames/second; 60fps x 752points/line = 45,120 points/sec

reverse-engineer-part-scanDTB can scan your products critical profiles using the latest measurement technology. Point clouds can be generated, imported and evalutated into a CAD model for further development.

We can confirm compliance with your tolerances and display the results with color coded printouts including: nominal part shape, tolerance bands, actual shape and deviations.

We can accommodate your CAD files to define nominal part shape.

reverse-engineer-data-develWith over 50 years of experience in engineering, design and fabrication, DTB can reverse engineer to develop your prototype and complete data package with materials and specifications that is ready for first article production or suitable for immediate procurement.

Technical Data Package Development

DTB can produce deliverable end items in 3D solids as well as production-level drawing packages.

Drafting skills include the preparation of drawings for Technical Data Packages (TDP) in accordance with MIL-DTL-31000, Engineering Drawing Practices in accordance with ASME Y 14.100 and Dimensioning and Tolerancing in accordance with ASME Y14.5M.

Materials, Processes, Joining Methods, Surface Finishes and Treatments

Reverse engineering programs are undertaken as a team effort in which the metallurgical laboratory participates as one of the team members.

We analyze every metallurgical characteristic (see Conformance Inspections) 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.

We also specify the governing specifications and participate in developing technical data packages and vendor qualification.

dtb-people-02Product Specification Evaluation / Substitution

DTB can evaluate your (current or) outdated material, testing and product specifications to determine if they are compatible with current materials, manufacturing processes and specifications.

Our experienced staff of engineer and metallurgists will evaluate your requirements and 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 and upgrading your current product designs.

Our experience, technical expertise, and innovation can help improve product reliability by evaluating historical product failures as well as through data collected during accelerated life testing — performed onsite at DTB.

Whatever the source, we can use the results to recommend alternative materials and or design and process improvements.

Dayton T. Brown routinely provides production improvement solutions to achieve shorter time to market.

Depending on your needs, you can select from the following types of product evaluation programs:

  • Drawing and Technical Documentation Review
  • Prototype Development / Evaluation
  • Design Substantiation Testing
  • Reliability Prediction
  • Failure Mode Effects and Criticality Analysis (FMECA)
  • Life Cycle Analysis
  • Qualification Testing
  • Design Optimization and Recommendations
  • Reliability / Production Lot Testing