Hexagon Streamlines MRO Reverse Engineering with Scanner-Software Integration

Hexagon's Portable Metrology Division has launched a new reverse engineering workflow specifically designed for maintenance, repair, and overhaul (MRO) teams. This integrated solution directly connects the ATLASCAN Pro handheld 3D scanner with Geomagic Design X software. Hexagon claims this combination can expedite the rebuilding of CAD models up to eight times faster compared to standard CAD tools, addressing a persistent challenge in aviation and defense MRO: the need to replace obsolete parts lacking original design data.

Civil aviation and defense MRO sectors frequently encounter situations requiring the reproduction of aging interior aircraft components. Items such as seat shrouds, armrests, tray tables, and hinges, which may be cracked or no longer in production, often need to be recreated. On-demand manufacturing, facilitated by reverse engineering, is increasingly being adopted. For example, the US Air Force has utilized reverse engineering and 3D printing to create replacement F-35 canopy frames for testing, and the Royal Air Force has incorporated its first in-house 3D printed part onto a Typhoon aircraft.

Hexagon highlights that while reverse engineering from scan data can minimize errors associated with manual measurements and outdated drawings, the process typically demands specialized CAD and scanning expertise to transform scan data into a functional 3D model. The company states that generating an accurate model using general-purpose CAD software can be three to eight times more time-consuming than with Geomagic Design X. This specialized software integrates direct scanner control with automated features like Region Segmentation, Modelling Wizards, and Auto Sketch, alongside NURBS surfacing, to convert complex shapes into editable, parametric CAD models with complete history.

Aziz Tahiri, global director of aerospace and defense at Hexagon, noted a growing interest from defense clients in mobile units that consolidate a scanning arm, reverse engineering software, and a 3D printer within a single container. This allows for on-site scanning, rebuilding, and repair of damaged parts. He added that the new workflow enables direct reverse engineering back into CAD within hours, a significant improvement over traditional multi-person, manual repair processes for single mechanical components.

The ATLASCAN Pro scanner is engineered for ease of use, requiring no specialist training, thus empowering MRO technicians and manufacturing engineers to scan smaller components from various angles in diverse environments like hangars or shop floors. It is designed to maintain accuracy in less controlled conditions while capturing fine details and high-density data with reduced post-processing needs. An Accuracy Analyzer within Geomagic Design X validates constructed surfaces against the original scan data at each step, mitigating rework and fit issues. Completed models can be transferred to popular CAD platforms like SOLIDWORKS, Siemens NX, Autodesk Inventor, and PTC Creo. Both the scanner and software are described as vendor-agnostic, allowing integration with existing third-party scanning devices and software.