Reverse engineering is an increasingly vital process in the world of manufacturing and product development. At Protomolecule, we often work with clients who need to recreate legacy or unavailable parts, update existing designs, or rapidly iterate on physical prototypes. That’s where reverse engineering comes in—and with 3D scanning and printing, it’s never been more accessible.
What is Reverse Engineering?
Reverse engineering involves analysing an existing physical object to understand its design, structure, and function. The goal is to capture that object in a digital format so it can be replicated, improved, or integrated into a new system.
For 3D printing, this typically means turning a real-world item into a digital 3D model that can be modified and manufactured using additive techniques like FDM or resin printing.
How We Reverse Engineer at Protomolecule
We start with high-resolution 3D scanning. Using our in-house structured light scanners, we can capture complex geometries down to sub-millimetre accuracy. This data is processed into a mesh file (typically STL or OBJ), and from there, we move into CAD work—cleaning the model and converting it into a solid format like STEP or IGES if needed for further editing or CNC compatibility.
In many cases, we also take the opportunity to strengthen the design, correct wear-induced distortions, or adjust tolerances for printability.
Common Use Cases
- Replacement parts – where the original manufacturer no longer supplies the item
- Pre-CAD legacy components – old machinery or tools with no digital documentation
- Product improvement – where the customer wants a stronger, lighter, or modified version of an existing part
- Fit and function testing – rapid prototypes used to test physical interactions with other products
File Outputs for Manufacturing
After reverse engineering, we can output your part in a range of file formats suitable for:
- 3D printing (STL, OBJ)
- CNC machining (STEP, IGES)
- Injection mould tooling (solid CAD with draft angles)
- Simulation and analysis (SolidWorks, Fusion 360, etc.)
Speed and Flexibility
Our Nottinghamshire-based workshop can scan, remodel, and 3D print prototypes in-house—often within a matter of days. This speed is ideal for customers needing urgent spares, small batch runs, or validation models before committing to tooling.
Need a part recreated?
We’ve helped everyone from engineering firms to hobbyists bring discontinued or unmodelled parts back to life. Get in touch with our team to discuss your project.