Challenge
When performance is measured in thousands of RPMs, precision is everything. The client needed a manufacturable CAD model and 2D drawings of a high-speed supercharging impeller (operating at 30,000 rpm).
The problem?
- No technical documentation was available: no CAD, no drawings
- The impeller’s complex aerodynamic blade profiles and ultra-tight tolerances made conventional measurement methods unworkable
- Even the slightest dimensional error risked imbalance, vibration or catastrophic failure during operation.
Our Solution
OTS deployed a two-stage approach combining 3D scanning and reverse engineering to guarantee accuracy and manufacturability:
- High-Precision 3D Scanning
- Used a laser-light scanner with 20 µm accuracy to capture the impeller’s entire surface
- Digitally preserved the intricate blade geometries and aerodynamic profiles in full detail
- Generated a high-resolution point cloud, eliminating reliance on approximation.
- Reverse Engineering Excellence
- Imported scan data into specialized Reverse Engineering software to create a fully parametric CAD model
- Produced manufacturing-ready 2D drawings aligned with production requirements
- Validated dimensional accuracy through simulation analysis, ensuring performance under real-world conditions.
Results & Benefits
- Manufacturing-Ready Deliverables: high-fidelity CAD model + 2D engineering drawings delivered with precision
- Guaranteed Accuracy: dimensional validation ensured safe and high-speed operation
- Faster Time-to-Market: eliminated trial-and-error prototyping; reducing both cost and lead time
- Mass Production Confidence: client gained assurance for safe integration into production at scale.
Impact
By harnessing cutting-edge 3D scanning and reverse engineering, OTS turned a complex, undocumented component into a digitally precise, production-ready solution. This solution empowered the client to accelerate innovation with safety, efficiency and confidence.
Impeller Scan Data & Reverse Engineered Model