From Reverse Engineering to Intelligent Design and Manufacturing: Integration Into Industry 4.0 for Sustainable Development

This article explores the strategic role of reverse engineering in the context of Industry 4.0, where advanced digital technologies, such as the Internet of Things (IoT), digital twins, artificial intelligence, and additive manufacturing, are transforming production processes. Reverse engineering enables the reconstruction of digital models of existing products or systems, providing opportunities to reduce development lead times, optimize maintenance, customize products, and support intelligent reengineering. A structured methodology is proposed to effectively integrate reverse engineering into digital value chains. This integration also contributes to sustainable development by promoting more efficient resource utilization, reducing waste, extending product life cycles, and improving the environmental performance of industrial systems. The study also highlights current limitations, risks, and future development prospects, drawing on case studies and advanced digital tools to assess the benefits in terms of cost, lead time, quality, innovation, and sustainability.