Understanding products with reverse engineering

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Anyone who wants to know how devices or machines work can get the answer to their questions with reverse engineering. This method is the exact opposite of conventional engineering.

What is engineering? Engineering includes all the higher-level activities of engineers that are used to develop, design and manufacture products. It also includes all the processes required to put new devices into operation.

But by breaking it down backwards, developers gain insights into the different elements and functionalities. For example, existing products can be improved. In general, the economy today offers enough starting points for reverse engineering. You can find out what these are in this article. 

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What is reverse engineering?

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Reverse engineering is a special technique with which components can be reproduced using computer-aided design (CAD) if the original construction plan is no longer available. 

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3D images of the parts are created so that they can be reproduced. 

A 3D measuring device measures the workpiece, whereby a three-dimensional grid model is created using CAD software and displayed on a monitor. Once the measurement is complete, the grid model is dimensioned. 

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Any part can be reverse engineered using these methods. 

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How does reverse engineering work?

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One company that specializes in reverse engineering is Q-Tech. 

Q-Tech uses various techniques to precisely and accurately measure the various workpieces and record a three-dimensional grid model.

The following paragraphs provide an overview of all measurement technologies and services from Q-Tech:
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Computer tomography

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Computed tomography can be used to measure complex components precisely and non-destructively. Thanks to the modern computed tomography installed in the METROTOM devices from ZEISS, it is even possible to take a look inside the components. To do this, the component in question is placed in the measuring booth and the scan is started. Within a very short time, Q-Tech is provided with meaningful 3D data for further quality analysis.

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3D coordinate measuring technology

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Thanks to 3D coordinate measuring technology, the reverse engineering company obtains precise and meaningful measurement results. Q-Tech's measurement services are always based on state-of-the-art technology. This not only provides you with significantly faster results, but can also reduce measurement costs, increase the quality of your products and create a clear competitive advantage.
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Optical 3D digitization

With the help of optical 3D digitization, Q-Tech can digitize three-dimensional geometries of components. There are virtually no limits to the size of the component. The reverse engineering company even offers to set up the measuring equipment on your premises to save time and transportation costs.

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Optical measurement technology

Even with optical measuring techniques, we achieve very high measuring accuracy. With the measuring microscopes from Q-Tech, for example, the company can make a quick statement about the component geometries and thus guarantee exact and precise results. 

The lighting can be variably adjusted and adapted to the component properties. 

In addition, the individual programming of the measuring microscopes also enables automated measuring sequences.

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Contour measurement

Q-Tech also relies on state-of-the-art technology for the contour and geometry measurement of components with the ZEISS Surfcom NEX 031 SD-14 N. 

For example, edges and radii are often among the function-critical features of a component. 

Q-Tech also measures these geometries precisely and reproducibly, even over long measuring distances. 

They provide you with meaningful results in the form of graphical representations with dimensional analysis.

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Roughness measurement

Q-Tech uses the ZEISS Surfcom NEX 031 SD-14 N for the roughness measurement, just like the contour measurement. 

The reverse engineering company is able to make precise statements about the quality of surfaces at any time in CNC mode.

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Additive manufacturing/3D printing

As part of additive manufacturing, Q-Tech offers you 3D printing for a wide range of applications. Whether you need jigs and fixtures, measuring components, prototypes, replicas or even entire assemblies, we are at your side.

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Reverse engineering software

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The basis for reverse engineering is the data from the computer tomograph or an optical 3D scan that Q-Tech generates from your components. With the help of professional software and many years of experience, the company can use this data to create error-free, precise CAD models in standard formats.

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Reverse engineering for software solutions

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Reverse engineering software solutions are primarily used to analyze and gain knowledge about the functionality of existing objects. However, this method can also be used to rebuild objects or products and improve them at the same time. This is possible, for example, with

• Software solutions
• Machines
• Military technology 
• Biological functions of genes.

Reverse engineering of software products in particular has been practiced for a long time. This involves attempting to convert the machine code of a program, often referred to as binary code, back into the original source code. 

Depending on the technique used, the knowledge gained from reverse engineering can be used to repurpose obsolete products, perform a reliability analysis, gain a competitive advantage or simply to explain something about how a product works to someone. Regardless of how the knowledge is used or what it relates to, reverse engineering is an attempt to gain knowledge about an existing object or software solution.

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What are the reasons for reverse engineering?

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The purpose of reverse engineering is clear: to understand how existing systems or objects work. But what are the reasons for this? 

In most cases, reverse engineering of software or hardware products is used to find a more cost-effective way of producing an existing solution. Or a product has been withdrawn from the market and is now to be replaced by a similar product. Reverse engineering is also used in IT to solve compatibility issues and to make hardware or software usable with other hardware, software or operating systems that were not actually suitable for it.

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How does the reverse engineering process work?

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The reverse engineering process depends on the specific object for which it is being carried out. Regardless of this, however, there are three general procedures that are common to all reverse engineering approaches. They include:

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• Replication: The collected information is transferred into a concept model in which the individual parts of the model fulfill their respective functions within the overall structure. The purpose of this step is to abstract specific information about the original into a general model that can serve as a guide for the design of new objects or systems. In software reverse engineering, this can take the form of a data flow diagram or a structure diagram.
• Correction: The model is evaluated and tested in various scenarios to ensure that it is a realistic representation of the original object or system. In software development, this is done as part of software testing. Once the model has been tested, it can be used to re-engineer the original object.

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3 examples of reverse engineering

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The basis for reverse engineering is the data from the computer tomograph or an optical 3D scan. With the help of professional software and many years of experience, the data can be created error-free and in precise CAD models in common formats.
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1. Non-destructive 3D measurement of components.
   Do you have a component for which you have lost or lost the construction plan? Then non-destructive 3D component measurement is just right for you!
   The components can be measured completely, without restriction or destruction. During this measurement, the devices work without contact, so there are no clamping and/or probing forces acting on the component.
   Each individual part and all geometries can be measured without any complex steps. Of course, this also applies to undercuts, narrow contours in low-lying areas and much more.

2. Inclusion of foreign materials
   Are there foreign materials, cavities or inclusions in your components? Then these can be detected in the shortest possible time using computer tomography without damaging or even destroying the component.
   Q-Tech prepares the results in different variants. The usual options are sectional views, transparent 3D representations or a classic report. Q-Tech lists the exact number, size and position of blowholes, inclusions or foreign materials.

3. Quality control
   Is your workpiece already fully assembled? But you still want to check that everything is in the right place?
   Computed tomography can be used to reliably check the correct assembly of even complex components consisting of many individual parts. Nuts, seals, ball heads etc. can be checked to ensure that they are fitted correctly, even if they are hidden under another component. This modern type of quality control sets completely new standards.

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Is reverse engineering legal? 

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Reverse engineering of hardware, machines or other physical products does not violate patent or property rights.

The various laws that relate to reverse engineering include:

• Patent law
• The copyright
• The Trade Secrets Protection Act (GeschGehG)

If reverse engineering is challenged in court, the original owner of a product, system or software code must prove that they are the intellectual inventor of the original product. Or that he owns the patent or copyright. In addition, the companies or persons who obtained their information through reverse engineering must prove that this was a legal method.

In general, reverse engineering is a very complex area as far as the legal situation is concerned. 

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Reverse engineering - a double-edged sword

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There are many legitimate use cases for reverse engineering on the market. Many problems can be solved and security gaps reliably closed. 

In general, reverse engineering is a very complex subject area. The steps involved in reverse engineering a product require a great deal of expertise.

However, reverse engineering also harbors a great danger. Depending on the product and the amount of analysis required, this can involve considerable costs. 

We will be happy to check whether reverse engineering is worthwhile for you. Simply get in touch with our contact persons.

This method also has its limitations. It is not possible to find an answer or solution to every question. Therefore, the cost-benefit ratio should always be checked first. Only then will it become clear whether reverse engineering is really worthwhile.

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