APJ 3D — Scan-to-CAD Reverse Engineering Checklist

Standard Operating Protocol for Physical-to-Digital Part Digitisation & Parametric Reconstruction

Phase 1: Physical Part Preparation & Metrology Scanning

Ensure physical part cleanliness; apply developer spray on highly reflective or transparent surfaces. Capture dense point cloud data using blue/white light structured scanners or laser trackers at sub-micron volumetric accuracy.

Phase 2: Mesh Processing & Polygon Clean-Up

Filter out outliers, noise, and scanning artifacts. Perform scan alignment and registration across multiple scans. Generate high-fidelity polygon mesh (.STL / .PLY) preserving critical datum features and sharp edges.

Phase 3: Datum Alignment & Feature Extraction

Establish functional Datum Reference Frame (DRF) matching original drawing intent or mating part alignment. Extract primary primitives (cylinders, planes, cones) and freeform B-spline surface patches.

Phase 4: Parametric CAD Modeling & Design Intent Recovery

Reconstruct fully parametric feature tree in solid modeling software (SolidWorks, CATIA, NX). Restore symmetric design intent and correct for physical wear, warpage, or manufacturing defects present in the legacy physical sample.

Phase 5: 3D Color Map Deviation Analysis & Verification

Overlay final CAD model back onto raw 3D scan data. Generate full-field color deviation report verifying that reconstructed surfaces stay within tight engineering tolerances (±0.05 mm standard).