From 3D Scan to CAD Model: The Complete Workflow
Reverse engineering succeeds when scanning, geometry cleanup, and CAD reconstruction are treated as one connected process.
1) Capture with downstream CAD in mind
Plan scan strategy around critical dimensions, mating surfaces, and hidden features. Capture overlap for registration and include reference geometry for alignment.
2) Preprocess and align
- Register scans into a single coordinate system.
- Remove stray points and sensor noise.
- Clip irrelevant geometry and fixtures.
- Validate scale using known dimensions.
3) Reconstruct a stable mesh
Build a clean mesh before CAD surfacing. Prioritize watertightness, edge continuity, and manageable polygon density. Keep a high-resolution archive copy before decimation.
4) Convert mesh to editable CAD
Use region segmentation to identify planes, cylinders, and freeform patches. Rebuild parametric features in CAD rather than relying exclusively on dumb B-rep conversion for production parts.
For complex organics, hybrid workflows (NURBS patches + mesh references) often provide the best balance of editability and fidelity.
5) Validate before release
- Compare CAD output to scan using deviation heatmaps.
- Check GD&T-critical features against tolerance bands.
- Run manufacturability checks for the intended process.
Key takeaway
High-quality scan-to-CAD output depends more on disciplined workflow steps than on any single software feature. Build repeatable checks into every stage.
Start your conversion workflow →
