3D measurement, 3D scanning, and reverse engineering — deviation map and inspection report

3D scanning is a non-contact, optical measurement of the geometry of a physical object. The scanner captures millions of points on the surface of the part, and software joins them into a triangle mesh saved as an STL file. This digital counterpart of the part is the starting point for quality inspection, CAD modeling, reverse engineering and 3D printing — with no contact and no risk of damaging the part being measured.

Reverse engineering is the recreation of technical documentation — a CAD model and a 2D drawing — from a physical part for which no files exist. The process combines a 3D scan with manual modeling in a CAD environment: the scanner mesh serves as a reference, and the engineer builds a solid on it with nominal dimensions. The result is a file ready for production, editing or archiving.

A 3D scan is an STL file — a triangle mesh representing the surface of the part together with its actual imperfections. It cannot be conveniently edited or dimensioned. A CAD model (STEP, SLDPRT) is a parametric or surface solid with nominal dimensions that can be modified, dimensioned on a drawing and passed on to production, for example to CNC machines. The scan is therefore a reference, and the CAD model is the documentation.

It depends on the technology. An STL file from a scan is fully sufficient for 3D printing or for making a casting mold — both methods work directly on the mesh. CNC machining (milling, turning) usually requires a STEP model created through reverse engineering, because CAM software needs clean geometry with nominal dimensions and tolerances.

Yes — it is one of the most common orders. We scan the part, create a CAD model from the scan and, if you need them, 2D technical drawings. We also recreate spare parts that are no longer available, as well as sections of damaged components — we reconstruct the missing geometry from the surviving surfaces and the function of the part. We can then manufacture the finished part right away in our own CNC machine park.

We agree on the model type with you before work begins. We can prepare a solid model, a surface model (for freeform shapes), or a fully parametric SolidWorks 2025 model in an SLDPRT file that you can freely edit in the feature tree. In a STEP file, we deliver a solid ready to use in any CAD system and for CNC machining programming.

The standard deliverable is an STL file with a closed, cleaned-up solid. Once the scope is agreed, we also provide a STEP model, an SLDPRT file for SolidWorks 2025, a deviation map, and a PDF measurement report. On selected projects, we also provide the raw point cloud and 2D technical drawings. We send all files electronically, within the scope agreed before measurement.

For simpler parts, the price of a 3D measurement starts at PLN 250. The upper limit depends on the scope of work: the size and complexity of the part, the type of output files, and whether you need a deviation map, a report, or a CAD model. We quote every order individually — just send a few photos of the part and a short description of the purpose, and we will reply within 48 hours.

Primarily the complexity of the geometry: a simple turned part is modeled faster than a housing with freeform surfaces. Other factors include the model type (solid, surface, or fully parametric), whether missing or worn areas need to be reconstructed, and whether a 2D technical drawing with dimensions and tolerances is needed in addition to the 3D model. We define the scope before quoting.

Yes. We scan smaller parts at our workstation in Janikowo near Poznań, but we perform on-site 3D scanning throughout Poland. Large, heavy, or permanently installed items — machines, molds, structures — are measured directly at your site, without disassembly or transport. The scanner is handheld and mobile, so we can take the measurement on the shop floor.

We set the lead time individually — it depends on the size and complexity of the part, the number of pieces, and the scope of post-scan work (CAD model, deviation map, drawings). We respond to inquiries within 48 hours and include a proposed date for the measurement and file delivery with the quote. If your order is urgent, say so in your inquiry — we will tell you what is realistic.

Yes. We work under non-disclosure agreements (NDAs) — we sign one before receiving any data if the project requires it. We treat all photos, scans, models, and geometries we receive as confidential, whether or not an agreement has been signed. This also applies to automotive and tooling projects, where design protection is especially important.

Yes. A deviation map is a graphic, color-coded visualization of the deviations of the scan from the CAD model: each area of the surface is assigned a color corresponding to the deviation value, so you can see at once where the part falls outside tolerance. We attach a PDF measurement report with values at selected points and cross-sections — ready for quality documentation.

Yes — this is the basis of our 3D quality inspection. We overlay the scan on the CAD model you provide and generate a deviation map and a measurement report. This is how we inspect production batches, verify prototypes and first articles from new tooling, and check whether a supplier made the part according to the documentation. Just send the model in STEP format with your inquiry.

We scan parts with matte and shiny surfaces, starting from 5 × 5 × 5 mm — we set the upper limit case by case, because we measure large objects on site. The material does not matter: metal, plastic, composite, wood, or stone. The only exception is gases — objects without a solid surface that cannot be measured optically.

The part should be cleaned of dirt, oil, coolant, and dust — anything on the surface will be scanned along with it. Before measurement, we coat black, shiny, or polished parts with a thin layer of white, removable scanning powder that mattes the surface; it is easy to remove afterward. If you have a CAD model or an old drawing, attach it to your order — it will shorten the work on the deviation map.