In brief
For spare parts, reverse engineering is the redesign of a component from an existing sample when the original is no longer available.
Contents
What is Reverse engineering?
If a manufacturer has discontinued a part, no longer exists or no documentation is available, reverse engineering can secure spare parts supply. All the information needed for new manufacture is obtained from an existing sample, ideally undamaged. Typical candidates are mechanical parts such as gears, shafts, bushes, impellers, seals and housing parts.
The process comprises measurement with gauges, a coordinate measuring machine or 3D scanner, determination of material, hardness and surface treatment, derivation of fits and tolerances from the function, and preparation of a production drawing. This is followed by sample production, first article inspection and a functional test in the plant. With worn samples, the nominal dimensions have to be reconstructed, which requires a technical understanding of the assembly.
Limits are set by intellectual property rights such as patents or registered designs, which must be checked before remanufacture, and by safety-relevant functions, for which a new assessment may be needed. Electronic assemblies with software can generally only be replicated to a limited extent. This entry does not replace a legal review in the individual case.
In practice: maintenance and procurement
For reverse engineering, the sample, any existing part drawings, installation position, mating parts, operating conditions and known damage patterns should be provided. The new drawing should then be archived as master data so that later reorders are possible without measuring again.
Synonyms and abbreviations: re-engineering · redesign from sample · backward engineering · part reverse engineering
Frequently asked questions
When is reverse engineering worthwhile for spare parts?
Reverse engineering is worthwhile when a part is no longer available, no equivalent alternative part exists and the plant is to be operated for some time to come. Purely mechanical parts are particularly suitable. The effort for measurement, drawing and first article must be weighed against the costs of downtime or a retrofit.
Is it permitted to replicate spare parts?
That depends on the individual case. If intellectual property rights such as patents, utility models or registered designs still apply, replication may be restricted. Contractual agreements with the manufacturer also play a role. The legal position should therefore be checked before remanufacture; the assessment of a qualified body is binding, not this entry.
Which steps does reverse engineering comprise?
Usual steps are a survey and functional analysis, measurement of the sample, determination of material and hardness, reconstruction of nominal dimensions and tolerances, preparation of a drawing or 3D model, sample production, first article inspection and a functional test. Only after successful testing is the part released and documented as a spare part.
What is the difference between reverse engineering and an alternative part?
An alternative part is a product from another manufacturer that is already available on the market and can technically replace the original. In reverse engineering, by contrast, a new part is drawn and manufactured on the basis of the original. It is usually used when no suitable alternative part can be found.