Precision Reverse Engineering & Metrology

PROJECT ID: TWS-01-RE

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Technical Data

Project Showcase

Download Case Study (PDF) Download STEP File (AP242)

The Challenge

Full reverse engineering of a consumer earbuds housing — laser scan, point cloud processing, and parametric reconstruction of both shells and internal PCB mounting geometry for injection mold toolpath generation.

The Solution

1:1 Reconstruction: Full-spectrum mapping for total geometric fidelity.

Metrology-Driven: Scale Compass verification for physical cross-validation.

±0.2 mm Precision: Manufacturing-grade tolerances ensuring seamless assembly and functional validation (Snugfit Tolerances).

Metrological Reconstruction

Reverse Engineering

Accuracy

±0.2 mm (Snugfit Tolerances)

Software

Scale Compass, Geometric Validation

Outcome

Production-Ready STEP Files

Methodology

The RE Workflow

Metrological Assessment

Tactile assessment utilizing precision Scale Compasses and digital calipers to establish primary datum points and verify global scale integrity prior to detailed measurement.

Tactile Metrology

Precision measurement captures full geometry at ±0.2 mm accuracy using Scale Compasses to establish a rigorous dimensional baseline.

Dimensional Calibration

Measurement synthesis and ratio verification using GOM Inspect produce a validated dimensional framework for reconstruction.

CAD Reconstruction

Feature-based parametric model rebuilt with geometric intent — not just a mesh conversion, but a true CAD model with metrological accuracy.

Validation & Delivery

GOM deviation report confirms dimensional accuracy, then STEP files are delivered with full inspection documentation.

Next Phase in Pipeline

Phase 2: Mold design & DFM

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