Reverse engineering an air intake
Old intake parts, provided as individual 3D scans, turned into drawings that today’s manufacturers could build, and that fit the original parts correctly.
From 3D scan files to new parts
3D scans as reference. Each piece of the intake was provided to me as its own 3D scan. I reverse engineered each one in SolidWorks as a subassembly of individually formed pieces, using the 3D scans as references. Drawings were made for each part and assembly. Overlaying the original 3D scans on the finished CAD gave an accuracy check.
Fit check. The part with the tightest fit was 3D printed, fine sanded and prepped for paint to protect it from UV, and test fitted. It fit as expected.
Manufacturing. The spin formed, wire formed and sheet metal parts were sent out to be made. Small adjustments were worked out with the different manufacturers so newer manufacturing methods could make old-style parts. The new parts fit the old ones correctly.