Reverse Engineering

For a price estimate on our 3D scanning services download our Cost Estimation Worksheet


We work with you to identify your problem and define how 3D scanning can be applied to the project whether it is reverse engineering, inspection, or measuring to name a few.


Through the use of our portable 3D laser scanner we can take live, full 360 degree scans of parts or even entire aircraft keeping accuracy to within .001 of an inch.


Through conversion of the 3D scan data to a 3D CAD model that exactly replicates the form of the object we can create file types necessary for any process of fabrication.


See Fabrication Capabilities With the accurate CAD model generated from the scan there are virtually limitless options for replicating the part quickly, accurately and efficiently.

What We Do

AirCorps Aviation Reverse Engineering uses state-of-the-art technology that allows for accurate scans of parts, both big and small, that can be used for the fabrication of new parts and inspection of original parts. Our process saves both time & money, and produces highly accurate results compared to traditional methods.

  • Outside contour development
  • Parts reproduction lacking dimensional drawings
  • Preservation recording
  • Quality control
  • Damage assessment
  • Aircraft dimensional tolerance and straightness
  • Part reproduction
  • Propeller blade inspection
  • Corrosion inspection
Contact Us:

Stefan Hokuf  |  218-444-4478, ext.121

Aeroscan 3D Reverse Engineering

3-D Scanning

We can all think of parts that are needed for restoring and maintaining our vintage aircraft that seem to be unobtainium and impossible to make. A common reason the part is impossible to make is because the part was made by craftsmen using techniques or machinery that are just as rare. With the addition of the 3D scanner to AirCorps Aviations machinery list, we can now digitally model these complex parts, drawn with a slide rule on pencil and paper, very accurately and efficiently. With this scanner we can combine the best of both the factory drawings and the actual dimension of an original part to make a replacement part that truly fits.

Benefits of Portable 3D Scanning

 No Rigid Setup Required

The part and scanner can be moved freely during scanning. Take it from place to place or use it inhouse or on site.


 Virtually limitless 3d scanning – no matter the part size, complexity, material or color.

Metrology-Grade Measurements

Accuracy of up to 0.0012 in., resolution of up to 0.002 in., high repeatability and traceable certificate.


No external positioning system, no arms, no tripod or fixture.

 Automatic Mesh Output

Model generation, right as you complete acquisition for realtime visualization of what is scanned.

Reverse Engineering Services

3D Scanning

What is 3D Laser Scanning?

3D scanners are tri-dimensional measurement devices used to capture real-world objects or environments so that they can be remodeled or analyzed in the digital world. The latest generation of 3D scanners do not require contact with the physical object being captured.  We utilize non-contact portable 3D laser scanners not only for their versatility but their speed.

3D scanners can be used to get complete or partial 3D measurements of any physical object. The scanner produces a digital, high density mesh that measures more accurately when compared to traditional measurement devices (rulers, calipers, micrometers, etc.)

Aeroscan’s expertise allows us to leverage this scan data and apply it efficiently and effectively to aerospace reverse engineering or inspecting applications.  Scanning objects in 3D is not difficult, however, knowing how apply that data to solve a problem is the expertise that we provide.

Bottom line – 3D scanning bridges the gap between existing objects in the real world and the digital environment that is the modern platform for engineering.  The aerospace industry can directly benefit from this with a faster return to service, return to market, improved quality and even product performance.

Want to learn 3D scanning basics and the workflow after scanning?  Visit our Solutions page where you can see illustrations.

What is 3D Laser Scanning?

After experiences with other types of 3d scanners. Aeroscan determined that 3D scanning with a portable hand held laser scanner not only provides the most versatility but the accuracy necessary for the majority of aerospace applications.  This type of laser scanning uses positioning targets placed on or around the subject to be scanned.  The targets act as coordinated positions that allow the scanner to move around the object in any direction without the restrictions of an arm or fixed tripod.  More importantly it does not limit the physical limit of the subject to be scanned.  However, if the subject to be scanned requires high tolerances between distances over approximately 12’, the addition of photogrammetry needs to be incorporated.  We are trained and can perform this additive service.

Scanner technical information:

  • Resolution: 0.0020 in. (0.050 mm)
  • Accuracy: Up to 0.0012 in. (0.030 mm)
  • File format output: .dae, .fbx, .ma, .obj, .ply, .stl, .txt, .wrl, .x3d, .x3dz, .zpr
  • Measurement rate: 480,000 measurements/ sec.

3D Printing

Most likely you’re familiar with the general principles of the additive manufacturing process—3D printing. However, if you’re asking how the 3D printing process is applied to reverse engineering or manufacturing/ fabrication process, Aeroscan can help.  For example, Aeroscan provides 3D printing as an additional service to aid those who would like to “rapid prototype” or test a difficult, costly actual part to machine or fabricate.  Remember, 3D printed objects need to originate from a 3D model.  Aeroscan’s ability to provide 3D scanning and CAD solid body modeling provides the groundwork to achieve your 3D printing needs.

3D printing’s technology in output mediums are constantly evolving.  Aeroscan can help you achieve your goals with printing in a variety of sizes, filament/material types.  For those reasons, we suggest that you contact us to discuss what type of printing is best suited and cost effective for your project.



If you are not familiar with 3D scanning you might not realize how useful it can be for inspecting, comparing and analyzing parts.  Our 3D scanners are a calibrated, metrology grade, extremely accurate pieces of measuring equipment.  When the physical dimensions of a part or object are captured, that data can be compared or inspected against other data.

Maintenance repair and overhaul (MRO) facilities can take advantage our ability to check – wear and tear analysis. Custom repair/ modifications. Data for as-built part documentation.  Verification of tooling before manufacturing usage.

If you are a manufacturer, you know how important quality control & first article inspections are. Aeroscan can help you scan your parts or assemblies and compare them to CAD models to insure compliance while supplying detailed reporting.

Looking for some more examples of what we inspect?  Visit our Applications page to see how 3D scanning can benefit you.


onstructing a CAD (computer aided design) model is an integral step in reverse engineering and sometimes in the inspections process(s).  It is also the most time consuming effort in that workflow. Aeroscan staffs full time CAD designers that are experts in translating 3D scan reference or 2D blueprints and recreating it as a 3D CAD model. Since we often fabricate parts our CAD designers also understand how to model tooling too.  We can not emphasize how critical it is to have aerospace experienced CAD designers modeling your part.

Aeroscan provides 3D CAD modeling as a service within the workflow for reverse engineering and inspections applications.  However, we can also provide CAD modeling as a separate service even if 3D scanning is not necessary.

Want to 3D print an object? You need a CAD model. Not clear how CAD modeling is applied to the Reverse Engineering process? Visit our Process page where you can see how CAD is applied to the typical workflow. 

Looking for some more examples of what we inspect?  Visit our Applications page to see how 3D scanning can benefit you.