Whether you’re looking to replace obsolete components, recapture control of your own products, or compete in new markets, we offer customized reverse engineering solutions to meet your needs!
Every component and assembly considered for reverse engineering is unique, but can be broken down into six fundamental categories for evaluation: Fit, Form, Function, Material, Coating, and Process. Each of these related to the others in varying degrees, based on your specific needs.
Identifying which of these are critical in your application is the key to establishing cost and timelines. For example, someone looking to replace a broken or old obsolete part may only care about fit and function and be willing to accept alternate form, material, coatings, or processes. Let’s explore the six fundamental categories of reverse engineering further.
Fit
Fit is often the most critical of the six fundamental categories as a part must fit in order to interface with the components around it. If a component or assembly does not fit, none of the other fundamental categories matter. Fit is both connections and clearances within a space and interrelates with both function and form.
It is important to identify all attachments, all potential interference points, and the enveloping space that a component or assembly is permitted to take up.
Fit is typically verified dimensionally, but is some instances may be checked simply by “fit check” against mating components and within an assembly.
Form
Form is the way a component or assembly looks or feels. Permitted the requirements of Fit are met, Form is often not critical for commercial and industrial applications. However, for defense, aerospace, power generation, and similar industries, weights and center of gravity may be of concern and therefore restrict or modify the Form. In these cases, Form often interrelates with Fit and Materials.
Other times, a product may have a “signature look” or an appeal that should be maintained for marketability. Other times, human factors and ergonomics define Form.
Form is typically verified dimensionally.
Function
Function is a broad category making up operability, movement, performance characteristics, environmental factors, desired failure modes, and anything else the component or assembly must “do”. Function is interrelated between all the fundamental categories as each one may be based on or drive a critical Function.
Functions need to be listed and then critical functions need to be identified. These critical Functions will be the basis for verification and may be subject to calculations, analysis, or physical testing. It is also important to determine whether any verifications will be recurring or in-process during production.
Material
Material in reverse engineering is the basis of Fit, Form, and Function. Material and drives or can be driven by process. And, it is heavily related to, and in some cases the same as, coatings.
Material selection however is different than material matching. If the sample material must be matched exactly, Positive Material Identification (PMI) must be performed. Methods for non-destructive PMI exist, such as XRF (X-ray fluorescence) but are often deemed unacceptable as they are not definitive tests and do not capture all critical material elements. Sacrificial material goes to a lab for analysis after all other reverse engineering steps are completed.
Material properties, such as grain orientation, microstructure, tensile strength, heat treatment, hardness, and surface roughness may also be considerations.
Determining whether Material is a critical category for reverse engineering and for ongoing verification is important, as material matching can drive cost of a reverse engineering project up unnecessarily. On the other hand, material properties can simplify Function verification via calculations as opposed to testing.
Coatings
Coatings consist of plating, passivation, paint, powder coat, grease, weld overlays, or any other applied layers beyond base material.
As mentioned above, Coatings are heavily related to Materials. Coating selection may be driven by or drive Function. Common Coatings may be easily identified by visual examination, whereas others may require XRF or lab analysis. Plating, paint and powder coat thicknesses are often easily measured for thickness. Weld build ops may require destructive evaluation to cut a section.
Similar to Material, Coatings matching can drive cost of a reverse engineering project up unnecessarily if it is not a critical characteristic.
Process
Process is the category that ties everything else together. Processes are defined by and for categories, and define others. Or in some cases, the process is the subject of the reverse engineering project.
In order to make a component or assembly, it is important to identify the processes that need to be utilized or developed. A round part that is made on a lathe may not require any process considerations. However, if that part needs a supplemental grinding operation that can’t be done in house will require locating a capable vendor or developing the ability in-house.
Products that need to be cast or forged may determine the types of materials available. Welding and weld overlay Coatings may be driven by or drive material selection.
Whatever your project, we’ll work together to determine the level of reverse engineering required and provide a customized quote to get the job done.
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