New software tools for reverse engineering parts based on three-dimensional volumetric scans

New techniques have been developed for automating the conversion of data, as obtained from 3D imaging modalities such as industrial Computed Tomography (CT, Micro CT), Magnetic Resonance Imaging (MRI), into rapid prototypes models and finite element meshes. These techniques can be used for robust reverse engineering of parts and for the numerical study of physical processes (e.g. structural performance, heat transfer...) on so-called legacy parts. The techniques guarantee the generation of robust low distortion meshes from 3D data sets of arbitrary complexity and currently up to seven different segmented parts can be meshed simultaneously. In addition, where two or more parts are in contact, the approach ensures that at the interfaces the meshes will conform; in other words there will be no gaps or overlaps between the mesh volumes. A number of cases studies will be presented including reverse engineering and simulation of mechanical performance of a windshield wiper component based on CT scans.