Reverse Engineering

Agile creation of digital design data, surfaces and 3D models using the latest laser scanning technology.

  1. AFD Systems
  2. What we do
  3. Reverse Engineering

AFD Systems delivers an end-to-end reverse engineering capability that combines 3D-scanning with 3D-modelling to accelerate design, validation and manufacture.

We offer this service across all sectors, undertaking site visits to undertake full vehicle or airframe surveys or to access parts and assemblies that need 3D scanning.

We also offer a 3D printing service of parts that have been reverse engineered to provide clients with trial parts, mock-ups and space-claims in a physical form.

From reverse engineering and digital modelling through to rapid prototyping and production-grade polymer components, our integrated approach transforms data into high-value, physical outcomes, enabling customers to move seamlessly from concept to completion.

Reverse Engineering expertise you can trust

Our reverse engineering capability spans our design and manufacturing teams, blending expertise in laser scanning, CAD modelling, and polymer additive manufacturing to deliver fully integrated, high-quality results.

The technology provides solutions for customers that enables the supply of obsolete parts or replacement parts with long-lead times. Reverse engineering is also used effectively during aircraft surveys and to assess damaged structure enabling the creation of digital geometry in support of future modification or repair.

Our reverse engineering capabilities:

3D-Scanning: Using hand-held laser scanning technology, we accurately capture surface geometry for reverse engineering. Our scanning capability allows us to record fine detail on small components or large assemblies with exceptional precision, ensuring complete digital traceability and dimensional accuracy.

3D-Modelling: We utilise industry-leading CAD platforms, including CATIA, SolidWorks, Siemens NX and Fusion 360, to create or refine detailed 3D models. Our engineers can reverse engineer scanned data into useable geometry or design new components from scratch, ready for prototyping, fit checks or production.

3D-Printing: We operate a range of polymer additive manufacturing systems, including Stratasys Fortus, Markforged FDM and Formlabs resin printers, alongside desktop systems for agile prototyping. This enables the production of high-quality polymer parts using a wide range of materials, each selected for specific mechanical or environmental performance.

We also provide Design for Additive Manufacturing (DfAM) training, helping customers understand material options, certification pathways and the engineering advantages of additive manufacturing.

Our process and methodology

We combine highly skilled design and manufacturing engineers with subject matter experts to deliver optimised 3D models and parts for our customers.

Our solutions are created using advanced digital toolsets, underpinned by expertise in scanning,  Design for Additive Manufacturing and printing across a range of additive manufacturing technologies.

This seamless process ensures:

  • Fast, precise digital capture and reverse engineering
  • Agile, iterative design and validation
  • Lightweight, high-integrity polymer components
  • Certified, production-ready parts

About AFD Systems

AFD Systems is a market-leading advanced engineering and manufacturing business, trusted by global aerospace and UK defence organisations.

With over 600 successfully completed engineering projects across 70 fixed-wing and rotary platforms, UAVs, drones and land systems, AFD delivers robust and technically-advanced solutions that drive the industry forward.

Headquartered in cutting-edge engineering facilities in North West England, AFD Systems is committed to engineering excellence, continuous improvement and a purpose to address complex challenges that contribute to a safer, more secure world.

Why choose AFD Systems?

AFD Systems acts as a seamless extension of client teams, combining advanced digital manufacturing technologies with deep engineering insight to accelerate project outcomes. Clients choose AFD Systems for:

  • Agile and efficient delivery
  • Reliable, trusted collaboration
  • High-quality, repeatable output
  • On-time, on-budget performance

our approach

Our approach is guided by a consistent set of values that ensures every project aligns with our clients’ mission goals:

  • CUSTOMER-CENTRIC | From beginning to end
  • INTEGRITY | In all that we do
  • INNOVATION | To remain in front
  • ONE TEAM | Making us stronger together

Standards and accreditations

AFD Systems is fully accredited and certified to deliver additive manufacturing solutions across a range of tightly controlled sectors. Our operations adhere to the following standards:

Related Case Studies

“AFD provided valuable support to a complex and challenging upgrade involving our customer, production and maintenance organisations, our US design office, and the responsible Military Aviation Authority. AFD always responded positively and effectively to support requests and their involvement in critical design reviews became essential in closing down queries and clarifying engineering decisions.”

Johannes Hien - Head of Design, Tenencia Aerospace Design

“We awarded the monument stress analysis to AFD owing to their extensive experience and knowledge in analysing this kind of structure and their pro-active approach to resolving technical difficulties often encountered in the design phase. The added value of using AFD was their pre-existing relationship with our customer (the DOA) enabling AFD to compile, check and verify the structural substantiation.”

Kevin Hann - Head of Design, JETMS

“AFD was able to bring extensive experience in composite design and structural testing to a complex programme. During the test campaign, the AFD CVE/Witness diligently carried out their duty to ensure test article conformity, and to execute the test in accordance with the Test Plan intent. Post‐test, AFD was able to process the results and deliver the required documents without delay, enabling GVH to receive the Supplemental Type Certificate in a timely manner.”

Jaco Loubser - Programme Director, Nova Systems

Sectors

AFD Systems is known globally for its work supporting customers in the aerospace and defence sectors, while it also has in-depth expertise in highly technical and regulated sectors such as medical, motorsport, nuclear, rail and space.

In the primary sectors of aerospace and defence, we provide engineering solutions for new design, modifications, repairs and reverse engineering for major airlines, special mission platform operators, military fleets, and VIP customers.

Aerospace
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Defence
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Space
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Nuclear
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Medical
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Rail
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Motorsport
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Trusted by organisations across the world