X-PRO Reverse Engineering Services​

Reverse Engineering involves taking existing physical parts and assemblies and creating CAD models and detailed toleranced drawings. 

Reverse Engineering Process

Understanding the function of the component or assembly is paramount to the reverse engineering process.  It is not enough to duplicate a physical part into CAD space, but you must know how the part/assembly interacts with surrounding components in the overall system.  This will allow the proper tolerance stacking information that is needed for dimensioned and tolerance prints. We have engineers certified in tolerance stacking using Geometric Dimensioning and Tolerancing (GD&T) and have experience based on actual design work to verify the efficacy of our process.  This background also gives us insight in to the likely design intent of areas of a component’s design.

Digitizing Components and Assemblies

Digitizing components and assemblies is achieved in our extensive temperature controlled metrology laboratory that has a full range of contact and non-contact measurement instruments.  We also offer on-site data collection when parts cannot come to us. Each of our engineering staff is trained in each digitizing technology so that they have a complete understanding of what is available and what is needed for any part or aspect of their work.  We employ tools such as hand instruments and gages, Laser Scanning, Structured Light Scanning, Long Range Laser Scanning, High Precision CMMs, Large Area Gantry CMMs, and Industrial CT Scanning. We have most of our scanning processes listed under our ISO17025 scope of accreditation.  This metrology based accreditation ensures that data that we take for you, will be correct and reliable to use on your laser model. The right laser scanning tools and parts are essential for the job. 3D Scanning aids the production and manufacturing process of your products and refines the accuracy of the model parts through state of the art scanning techniques.

The Right Equipment, Staff, Experience, and Knowledge

3D Engineering Solutions combines the right equipment, engineering staff, experience and knowledge to tackle the most difficult reverse engineering work.  Everything you need is under one roof. Our engineer-metrologists are proficient in all of the technologies that we use and have the experience base to perform the work efficiently.  Our large staff is configured to handle your large projects with ease. We have purchased and continue to evaluate all of the latest data collection technologies available. We have completed thousands of metrology and reverse engineering projects for hundreds of customers and would like the chance to complete yours as well.  Our fully trained staff are able to complete projects from beginning to end each by themselves. This allows them to be efficient in the completion of your project. Solutions are supported by 3D Engineering Solutions in support of legacy military equipment as well as other industry needs. We can take legacy drawings that are difficult to read and/or existing or damaged physical components and re-create functional CAD models and drawings.

The Project Flow

1. Tell us about your project

Describe your project, estimate the number of hours needed, the duration, and software requirements.

2. Pre-qualified expert freelancer

One of our engineers will contact you to discuss your project and gather more details.

3. Deposit & work

Agreement will need to be signed and payment deposit made in order to begin a project.



Reverse Engineering refers to the process of re-creating design drawings by taking measurements and/or scans of the part itself.  It’s a simple, two-step process: 1) scan the object, 2) create a 3D model of the object.



The process of creating a CAD model for reverse engineering services requires some understanding of the original designer’s thought process. For example, one must make assumptions about whether a part is supposed to be symmetrical or perfectly round in shape. With reverse engineering, the goal is often to produce a CAD model of very high quality surfaces, or “idealized”, where faces are perfectly flat, holes are perfectly round and surfaces are all seamlessly blended into one another. This makes it easier to create feature-based models along with dimensioned 2D drawings. This is different than “as-built” modeling, where the goal is to intentionally model a part’s flaws wherever they exist.



Common reasons include: 

  • To make a part or other item cheaper
  • Replicate a one-of-a-kind part
  • Analyze a competitor’s product
  • Create machining drawings for a handmade prototype
  • Create a nominal model to be compared against for inspection
  • Make changes and improvements to a product’s design
  • Preserve and document handmade molds & obsolete parts
  • Blueprint parts for government certification
  • Create the mold for a part



Because of the high quality models produced during the reverse engineering process, the models happen to be very versatile. Among the many things that are possible:

  • Machining & molding
  • 3D printing
  • Making changes to the design
  • Patent drawings
  • Exploded 3D visualizations and animations
  • Comparisons with other parts or scans
  • Can be used to design mating parts or packaging
  • Drawings can be sent overseas for manufacturing instead of the part



Great news! With different laser scanners, we are able to scan huge parts to tiny parts and everything in between. Examples of scanning we have done range from windows and large monuments to things as small as a coin. We are also able to scan complex organic surfaces such as an artistic human bust.

Different scanners are used depending on the application. Most of our scanners are portable, therefore we are able to scan at the your location. But if your item is small enough, it is usually cheaper to ship the item to one of our scanning offices. This is because our offices are set up to scan items quickly and economically.


Benefits of 3D Scanning for Reverse Engineering

  • Very accurate method of capturing a physical part – up to 15 micron (.015mm /.00059”) accuracy
  • Capture complex and organic shapes quickly
  • Non-contact methods ensure accuracy and integrity of the data captured.
  • Much faster method of generating surface and solid models
  • Modify an existing design from 3D Scan data
  • Design parts to fit up to or integrate with an existing object
  • Capture very small details – down to 16 micron (.016mm / .0006”) point spacing


Reverse engineering deliverables

  • Point cloud data – color or non-color – PTS, PTX, XYZ
  • Polygon models – STL, PLY, OBJ, VRML
  • 3D Surface model –IGES, STEP
  • Feature based solid model & assemblies – IGES, STEP, ParaSolid, SolidWorks
  • Hybrid CAD model (surfaces and solids) – IGES, STEP, ParaSolid, SolidWorks
  • Photo realistic renderings
  • Drawings
  • Animations

How Can X-Pro Help With My Project?

X-Pro helps clients with one-time and ongoing project needs. Our specialties include 3D modeling, 3D design, CAD drafting, 3D animation, engineering and 3D renderings, 3D industrial design, prototype design, 3D printing design, mechanical design, architectural design, structural design, 3D interior design, and CAD landscaping design services.

Our CAD designers and drafting contractors work with AutoCAD, SolidWorks, Autodesk Inventor, Maya, 3ds Max, CATIA and many other types of software. Submit your project description and work with a pre-qualified 3D artist, CAD designer, drafter, 3D modeler, 3D animation or engineer specialized for your project needs.

FAQ for your new project

Why X-Pro?

We connect you with the best designers in the business, and we offer the most comprehensive set of services for inventors you’ll find anywhere. We take the guesswork out of online design services, and let you focus on what’s important.

How do private projects work?

Simple. Just send us a project brief and we will provide you with a design quote from a pre-qualified designer for your project.

Who can see my project?

Private projects are entirely confidential. Only you and the designer that you will be working with will see your project description, file attachments and submitted work.

Do I own the designs & IP?

Yes. Our legally binding terms of service assign the ownership of intellectual property (IP) from the designer to the service buyer for any paid designs.

Do you offer manufacturing services?

Yes we do! We offer a range of  manufacturing services, including 3D printing, rapid manufacturing and conventional injection molding.

How is a design project different from hourly services?

Design projects are limited-term projects with a concrete budget, based on an upfront quote from the CAD designer. Hourly services are for ongoing work that generally have an open work scope.

Will designers sign a NDA?

We’ve got this covered. Our legally binding terms of service covers freelancer non-disclosure. Freelancers on X-Pro have agreed to and are bound by the terms of non-disclosure that are outlined in our terms of service.

Got a question? Get in touch

We’re here to help. Send us an email or get a personalized quote.


24 Hours a day

7 days a week

365 days a year

22206, Arlington VA
571 581 2377