Reverse Engineering: Technology of Reinvention
I.D. # C0559 Duration 2 Days

During the past decade reverse engineering has become a common and acceptable practice utilized by many original equipment manufacturers and suppliers. This course focuses on the application of modern technologies used to decode the design details and manufacturing processes of an existing part in the absence of the original design data. It emphasizes the real-life practice of reverse engineering in the aerospace industry from both scientific and legal points of view. Attendees will learn the applicability and limitations of reverse engineering through case studies and hands-on exercises.

Various measurement instruments, ranging from traditional micrometers to computer-aided laser probes, will be compared for their merits and shortcomings. The statistics of dimensional measurements and the acceptable tolerance of variations, with emphasis on industrial standards in real-life practice will be discussed. Material identification, manufacturing process verification and the system compatibility of the subject part to be reverse engineered will be covered in substantial detail. In addition, the materials specifications will be exemplified as useful supporting documents for substantiation data.

Note: Participants should bring a calculator for in-class exercises.

Learning Objectives
By attending this seminar, you will be able to:
  • Define the critical elements of reverse engineering
  • List the measurements and analyses required to duplicate/reproduce an OEM part by reverse engineering
  • Recognize if an OEM part can be duplicated/reproduced by reverse engineering
  • Judge if a "duplicated" part will meet the design functionality of the OEM part
  • Evaluate the feasibility of a reverse engineering proposal/project
  • Describe and implement a process to duplicate/reproduce a part by reverse engineering

Who Should Attend
This seminar is designed to assist individuals in various industries including, but not limited to, automotive, aerospace, off-highway, motorsports and parts brokerage firms. Corporate senior executives, engineering managers, engineers, technicians, government inspectors, sales managers, salespersons, lawyers and legal counselors will find the course relevant and informative.
Participants should have an undergraduate degree or equivalent experience/knowledge.
Seminar Content
  • Introduction
    • Historical background
    • Reverse engineering vs. machine design
    • Three basic requirements: form, fit and function
  • Geometrical Form
    • Dimensional measurement
    • Precision instruments of measurement
    • Tolerance
    • Virtual exercise of geometrical modeling
  • Material and Process Identification
    • Chemical composition identification
    • Manufacturing process verification
    • Materials specification substantiation
    • Machining process identification
  • Data Process and Analysis
    • Statistical analysis
    • Statistical exercise
    • Case study of statistical confidence
    • Reliability
  • Demonstration and Exercise
    • Demonstration of scanning
    • Hands-on exercise of reverse engineering
    • Case study
  • Regulations and Certifications
    • Government regulations
    • Industrial standards
    • Certification requirements
  • Fit and Function
    • System compatibility
    • Critical performance
    • Vendor substantiation
    • Safety and damage tolerance
  • Acceptance and Legality
    • Evolving industry trends
    • Moral and legal issues
    • Examples - legal precedents

Instructor(s): Wego Wang

Dr. Wang is currently an aerospace engineer in the Engine Certification Office of the Federal Aviation Administration, where he serves as the focal point for Parts Manufacturer Approval. He has been a technical instructor and a researcher in mechanical engineering and materials science since the 90s. Dr. Wang taught at Northeastern University and is currently an adjunct faculty at Boston University and the University of Massachusetts - Lowell. He received many awards, commendations and recognitions from the Army Research Laboratory, the FAA and other institutions. Dr. Wang authored or co-authored over 40 technical/professional articles, and presented lectures/reports at numerous seminars/conferences. Active with professional societies, he is on the executive committee of ASM International Boston Chapter and was the 2005-06 Chairman of the Chapter. He also served on the executive committee of TMS Boston Section, where he was president from 1993-95. Dr. Wang has a B.S. in Mechanical Engineering from National Cheng - Kung University, a M.S. in Mechanical Engineering from National Taiwan University, and a M.S. and Sc.D. in Materials Science and Engineering from Massachusetts Institute of Technology.

Fees: $1299 SAE Members: $1169


CEU 1.3