Ditch the calipers and use a 3D scanner for reverse engineering!

Edward Van Zyl, a seasoned 3D scanning and printing expert from Manitoba, heads the company Dreamworks 3D Printing and Scanning. With extensive expertise in vintage car restoration and customization, he is enthusiastic about utilizing state-of-the-art equipment to capture intricate details of automotive components and then utilizing software to generate accurate 3D models. This article, courtesy of Shining 3D, deep dives into the tips utilized by Edward for scanning with the EinScan HX Hybrid Light Source Handheld 3D Scanner and the reverse engineering of car parts through the use of Geomagic Essentials and Fusion 360.

Scanning And Printing An Arrow 50 Scooter Part

Edward embarked on a projet to 3D scan and reverse engineer an Arrow 50 scooter part and then 3D print. He chose the EinScan HX Hybrid Light Source Handheld 3D Scanner for this reverse engineering project.

In the 3D scanning process, Edward provides a small tip: utilizing miniature pyramids as markers rather than some of the markers that need to be put directly onto the object. This has the advantage of saving time and cost, as it eliminates the need for post-scan cleaning and the small pyramids can be reused. You may download files of pyramids here.

Arrow 50 Scooter Part & Pyramid Markers Photo: Courtesy of Shining 3D

In laser scan mode, EinScan HX has a maximum scan speed of 480,000points/s. It just took around 12 minutes to complete the whole scan of the component. And the laser scan mode of EinScan HX makes the scanned data accurate up to 0.04mm, thus you get a very accurate model for subsequent work.

Scan File generated by EinScan HX Photo: Courtesy of Shining 3D

Below is the 3D printed part from Bambu Lab X1-Carbon Combo 3D Printer.

3D Printed Part Photo: Courtesy of Shining 3D

Cutting A Fender Using Geomagic Essentials

Edward’s goal was to cut a fender and make sure it was the right size for installation. Usually, he will print out the part for test, and in this case he offers an easy-to-print and material-saving trick.

​He creates a small offset about 5 mm or even less, and cuts the part again, so that he gets a tiny piece of the fender, but maintains the geometry he need. 3D printing this thin piece was just as good for installation testing, and using only a minimal amount of printed material.

Cutting the fender in Geomagic Essentials Photo: Courtesy of Shining 3D

Small Offset of Fender in Geomagic Essential Photo: Courtesy of Shining 3D

Reverse Engineering An Engine Using Geomagic Essentials And Fusion 360

Furthermore, Edward uses Geomagic Essentials to extract features on the engine, and then using Fusion 360 to model the three holes in which he wants to simulate the mounting bolts.

Extracting features in Geomagic Essentials Photo: Courtesy of Shining 3D

One thing to keep in mind here is that you need to maintain the mesh and the extracted features in uniform coordinates. This step ensures that the extracted features can be overlayed on the mesh in the right position. After extruding two cylinders of different sizes and modeling some threads, the mounting bolt is done.

Modeled Mounting Bolts and Brackets Photo: Courtesy of Shining 3D

This is basically how to go from scanning to printing of a part; how to use a mesh and model mounting bolts in Geomagic Essentials and Fusion 360. And it is clear how much can be done with a bundle of 3D scanners and softwares.


You may find more operation details in the playback video. If you found this content useful, please follow Shining 3D's webinar pages, so you won’t miss out on more information.

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