RevWorks is a CAD-Driven Reverse Engineering software solution for SolidWorks users. RevWorks is a fully integrated Gold Partner solution and has been since 1997. RevWorks empowers its users to utilize a 3D digitizer as a real-time input device for SolidWorks. Physical objects are reverse engineered into a CAD model by applying methods similar to approaches employing traditional hand measurement tools. The end result of the application of RevWorks and a 3D digitizer is a modifiable, history-driven solid model. The resulting editable CAD model is the most talked about benefit gained by RevWorks users.

Once underway, the differences between CAD-driven reverse engineering and using a digitizer in the traditional way are quite apparent. With data collection occurring real-time, RevWorks ties the data directly into CAD functionality. RevWorks takes into consideration that the input is derived from an object. For example, a sketch or construction plane could be defined with a minimum of three positions in space. Since digitizers have a range of tolerance to the actual, a user might collect a dozen points in order to help average out any deviation in point collection. In a plane creation function RevWorks allows the user to collect from 3 to (n) points and develop the plane. When it comes to calculating the best fit for the plane, the collection of more than three points improves accuracy, though collecting more than a few dozen points provides no enhanced value. Defining a construction plane from a point cloud with a million points is no more accurate. In fact, having the additional information can be burdensome.

RevWorks' ability to allow a user to acquire only the data they intend to use helps further differentiate its CAD-Driven Reverse Engineering approach from using a digitizer as a standalone data collector. Revware's customers often have experience with other reverse engineering methods. Tom Welsh, Revware's VP of Development, recalls one customer who developed a rock-drilling bit. The original bit had been repaired and modified in the field and no working drawings o the original design had ever been made. Before approaching Revware the customer invested in a laser scanning and point cloud, but generated no results with the data. A staff member at Revware, using RevWorks for SolidWorks, took only five hours to capture the design intent and create a solid model acceptable to the customer. "Here is a classic case where a product is refined in the field. We helped this client get the optimized product into production. Additionally, when a future improvement is made they now have a modifiable CAD model to work from." CAD-Driven Reverse Engineering with RevWorks makes it easy to recapture design intent, even from severely degraded parts.

What is CAD-Driven Reverse Engineering?

Since long before the advent of CAD systems, working drawings have been derived from physical models. A classic example is the taking of lines from scale models to develop sailing vessels. This data was then painstakingly modified on the lofting floor to develop a fair hull form. Not surprisingly, the most common approach today for addressing the need to develop a CAD model from an object is to manually measure pertinent dimensions with calipers, micrometers, rules and any other instrument necessary. When accuracy is not a concern, even the eye of the CAD operator is utilized. Manual methods can work nicely for objects with minimal features, but as the complexity of the part's geometry increases the effort needed to accomplish the task can become prohibitive.

Three-dimensional digitizers of all types are utilized to extract coordinate data from solid objects and drive reverse engineering strategies. The traditional approaches begin by collecting a complete set of (x,y,z) locations that represent the shape of the object. Once collected, these point sets are sent in mass to a CAD system as point data, or, filtered and manipulated by software products that specialize in preprocessing point data being passed off to the CAD system. The term "point cloud" is used to describe point sets with a high magnitude of points; a high-resolution laser-scanning device will create point clouds with millions of data points. Getting the desired results from the data is a task that can require a tremendous amount of manpower and access to specialized equipment and software. While point clouds are readily meshed with polygons, the development of modifiable CAD models has not proven practical.

CAD-Driven Reverse Engineering is a fresh approach to a traditional process made practical by Revware. CAD-Driven Reverse Engineering is realized by tightly integrating 3D digitizers and coordinate measuring machines with CAD. The integration is especially powerful with integration to parametric CAD. CAD-Driven Reverse Engineering empowers its users to utilize a 3D digitizer as a real-time input device for their CAD system. Physical objects are reverse engineered into a CAD model by applying methods similar to approaches employing traditional hand measurement tools. The end result of the application of this integrated process is a modifiable, history-driven solid model. This result has been a goal for practitioners of reverse engineering for quite some time.