Analysis of the Accuracy of CAD Modeling in Engineering and Medical Industries Based on Measurement Data Using Reverse Engineering Methods

The reverse engineering (RE) process is often necessary in today’s engineering and medical industries. Expertise in measurement technology, data processing, and CAD modeling is required to ensure accurate reconstruction of an object’s geometry. However, errors are generated at every stage of geometric reconstruction, affecting the dimensional and geometric accuracy of the final 3D-CAD model. In this article, the geometry of reconstructed models was measured using contact and optical methods. The measurement data representing 2D profiles, 3D point clouds, and 2D images acquired in the reconstruction process were saved to a stereolithography (STL) model. The reconstructed models were then subjected to a CAD modeling process, and the accuracy of the parametric modeling was evaluated by comparing the 3D-CAD model to the 3D-STL model. Based on the results, the model used for clamping and positioning parts to perform the machining process and the connecting rod provided the most accurate mapping errors. These models represented deviations within ±0.02 mm and ±0.05 mm. The accuracy of CAD modeling for the turbine blade model and the pelvis part was comparable, presenting deviations within ±0.1 mm. However, the helical gear and the femur models showed the highest deviations of about ±0.2 mm. The procedures presented in the article specify the methods and resolution of the measurement systems and suggest CAD modeling strategies to minimize reconstruction errors. These results can be used as a starting point for further tests to optimize CAD modeling procedures based on the obtained measurement data.