Reverse Engineering Services for Parts with No Usable CAD
Some parts are still mission-critical long after the drawings are gone.
Statt Engineering provides reverse engineering services for complex, legacy, obsolete, damaged, modified, and undocumented components. Using 3D laser scanning, Faro Arm CMM scanning, CAD reconstruction, dimensional verification, and precision CNC machining, we help aerospace, defense, medical, industrial, and automotive teams rebuild what they can no longer source or document.
3D laser scanning
Faro Arm CMM scanning
MetraScan 3D scanning
CAD reconstruction
Surface and solid modeling
Dimensional verification
CAD-to-machining workflow
AS9100D quality system
ITAR support
NIST compliance
Missing CAD should not stop production
A missing file is not a small inconvenience when the part keeps a program moving.
Maybe the original supplier is gone. Maybe the drawing is incomplete. Maybe the part has been modified in the field and no one trusts the revision history anymore.
Statt Engineering helps turn physical geometry back into usable engineering data, then moves that data into manufacturing. The goal is not a pretty scan. The goal is a part, tool, or component your team can inspect, machine, document, and use.
Our Capabilites
Reverse engineering capabilities
3D laser scanning
High-resolution scanning using MetraScan and Faro Arm tools to capture physical part geometry, complex surfaces, and inspection data.
Surface and solid modeling
Reconstructed CAD from physical parts, scan data, damaged components, obsolete tools, or undocumented geometry.
Dimensional verification
Inspection-grade comparison between scanned geometry, CAD models, and manufactured parts.
Design optimization
Updates to legacy designs for manufacturability, performance, durability, or practical production requirements.
CAD-to-CAM integration
A connected workflow from scan data to CAD modeling, CAM programming, and CNC production.
Precision part reproduction
Machining support for recreated parts, tools, fixtures, or components once the model and manufacturing path are validated.
From physical part to build-ready data
Reverse engineering only works when the process is controlled. A scan is the start, not the finished answer.
Process flow:
- Part review
Understand the application, material, failure point, missing data, available drawings, tolerance expectations, and manufacturing goals. - 3D scanning or CMM capture
Use Faro Arm CMM scanning, MetraScan 3D laser scanning, or inspection methods to capture usable geometry. - Data cleanup and comparison
Review scan quality, damaged areas, wear patterns, deformation, and deviations from any existing drawings. - CAD reconstruction
Rebuild the part as surface or solid CAD geometry that can support engineering review and manufacturing. - Design optimization if needed
Improve legacy features for manufacturability, fit, performance, or updated production methods when the project requires it. - Dimensional verification
Validate the reconstructed model against the physical part, known requirements, or inspection targets. - CAD-to-cut handoff
Move the approved model into CAM programming and CNC production when manufacturing support is required.
Faro Arm CMM scanning
For oversized molds, master patterns, layup tools, and fixtures that require extended length, width, or depth.
MetraScan 3D laser scanner
Used for probing, contact-based measurement, dimensional capture, and inspection support for mechanical parts.
CAD/CAM workstations
Used to capture complex geometries, high-resolution point clouds, surface detail, and part shapes that are difficult to document manually.
CMM and inspection verification
Used to reconstruct, validate, optimize, and prepare files for machining workflows.
Our Reverse Engineering Equipment
Scanning, metrology, and CAD tools built for accuracy
Reverse engineering is only useful if the data can be trusted. Statt Engineering uses scanning, metrology, CAD, CAM, and inspection tools to capture geometry, rebuild models, and verify the result before manufacturing.
Not just scan data. Usable CAD.
A point cloud is not enough for most manufacturing teams. Statt Engineering rebuilds physical geometry into CAD models that can be reviewed, modified, verified, and used for machining. Depending on the part, that may include surface modeling, solid modeling, tolerance review, feature cleanup, or design optimization.
Composite tooling for demanding manufacturing environments
Aerospace
Recreating parts without CAD
Rebuilding obsolete components
Reproducing legacy aerospace parts
Reverse engineering defense components
Recreating damaged or modified parts
Rebuilding CAD from physical geometry
Reverse engineering tooling, jigs, and fixtures
CAD reconstruction for manufacturing
Inspection-grade part comparison
Scan-to-CAD modeling
CAD-to-CNC part replication
Design optimization for manufacturability
Reverse engineering medical components
Industrial equipment part reproduction
Automotive and motorsport part replication
AS9100D quality system
ITAR support
NIST compliance
Dimensional verification
CMM inspection support
Faro Arm scanning
MetraScan 3D scanning
CAD model validation
CAD-to-CAM handoff
Precision CNC production
Documentation and traceability support
Reverse engineering backed by inspection and quality discipline
For aerospace, defense, medical, and industrial work, reverse engineering is not just a geometry exercise. The recreated model and manufactured part need inspection discipline behind them.
Statt Engineering supports reverse engineering projects with dimensional verification, CMM and inspection support, CAD comparison, and quality workflows aligned with AS9100D, ITAR, and NIST requirements.
Our Tools
Why manufacturers choose Statt for reverse engineering
Engineering-first support
Statt does not only machine what is sent over. We can support manufacturability, tool design considerations, validation, and practical production planning.
Large-format 5-axis capability
Fast response when capacity is tight
Statt emphasizes small-business agility with elite aerospace quality. This is especially important for overflow work and short-run or prototype tooling.
Reverse engineering for legacy tools
Statt supports tooling reproduction when original CAD, drawings, or master data is missing.
Compliance-ready manufacturing
Need to start from the final product?
From reconstructed model to machined component
Reverse engineering often fails at the handoff between data capture and manufacturing.
Statt Engineering closes that gap with CAD-to-CAM integration and in-house precision CNC machining. Once the model is reconstructed and verified, our team can support programming, machining, inspection, and final part replication.
Reverse engineering FAQs
Can Statt Engineering recreate a part without CAD?
Yes. Statt specializes in reverse engineering complex, legacy, and undocumented components when CAD files or documentation no longer exist.
What reverse engineering tools does Statt use?
The documented tools include Faro Arm CMM scanning, MetraScan 3D laser scanning, CAD/CAM workstations, and CMM and inspection verification.
Can Statt create CAD from a physical part?
Yes. Statt supports surface and solid modeling to reconstruct CAD from physical parts.
Can Statt machine the part after reverse engineering it?
Yes. Statt’s reverse engineering workflow includes CAD-to-cut integration, CAM programming, and CNC production.
Can Statt improve a legacy design?
Yes. Statt specializes in design optimization in a reverse engineering capability, including improving legacy designs for performance or manufacturability.
Does Statt support aerospace and defense reverse engineering?
Yes. Statt supports aerospace and defense applications, has a AS9100 certification, and is ITAR compliance for sensitive applications.
Can Statt support damaged, obsolete, or modified components?
Yes. Statt supports obsolete, damaged, modified, undocumented, and legacy parts.
Have the part, but not the file? Send it to us.
If you need to recreate a legacy component, rebuild CAD from a physical part, verify geometry, or move from scan data into precision machining, Statt Engineering can help define the cleanest path from physical part to build-ready data.