Environmentally Sustainable Machining of Complex Parts Using 3D Scanning and Virtual Models

Abstract In multi-process manufacturing, ensuring part accuracy and meeting production requirements depends heavily on correct repositioning, basing, and assessment of the geometry state from prior operations. The risk of error during these steps is particularly high in single-unit production, where rework is costly and time-consuming. Complex-shaped parts pose an additional challenge, as the process planning time often exceeds actual machine time. To address these issues sustainably, 3D scanning and reverse engineering are increasingly applied—not only as tools for in-process geometry control but also for creating virtual models that integrate directly into computer-aided manufacturing workflows. Their use reduces material waste, prevents unnecessary machining, and supports energy-efficient operations. In this article, the machining of a custom aluminum alloy casting is presented, where the initial 3D model was inaccurate. To meet tight precision requirements and minimize environmental impact, reverse engineering was employed to define the exact position of target geometries within the provided casting, thus enabling accurate and resource-conscious subtractive machining.