Devising an approach to prototyping a worn or deformed aviation part based on reverse engineering

Authors

DOI:

https://doi.org/10.15587/1729-4061.2026.351776

Keywords:

reverse engineering, 3D scanning, geometry reconstruction, geometry accuracy, reconstruction algorithm, digital model, surface control

Abstract

This study estimates the geometric accuracy of an aviation part's digital model constructed from a portrait. The task addressed is to reproduce the geometry of an aviation part based on its original dimensions.

A procedure is proposed for reconstructing the geometry of aviation parts that have wear or deformation (changes in size and shape from the rated ones) and assessing the accuracy of a digital 3D model using RE methods. An approach to digitizing test parts using RE is suggested in the form of a general algorithm for generating data on a digital 3D model of a test part. The algorithm includes 3D scanning, point cloud processing, polygonal model construction, analysis of “shadow zones”, and additional iterations with a change in the position of the part. The latter allowed for high-precision identification of the geometry of the original test part for building a digital 3D model.

The approach was tested on the example of an impeller using a HEXAGON Absolute Arm coordinate measuring machine with an AS-1 laser scanner, which provided a scanning accuracy of ±0.05 mm and a point density of up to 0.026 mm. Current geometry control and correction of deviations using a color map were carried out at each stage of the algorithm implementation. That has made it possible to minimize errors, eliminate “shadow zones”, and restore the lost geometry of the original impeller when building a digital 3D model. The final control of the constructed model showed robustness of the results within the range of ±0.05 mm.

The results could make it possible to prototype test parts with signs of wear or damage with a reproduced high-precision geometry within the tolerance for the manufactured size.

Author Biographies

Kateryna Maiorova, National Aerospace University “Kharkiv Aviation Institute”

PhD, Head of Department

Department of Aircraft Manufacturing Technology

Sergiy Zaklinskyy, National Aerospace University “Kharkiv Aviation Institute”

PhD, Associate Professor

Department of Aircraft Manufacturing Technology

Oleksandra Kapinus, National Aerospace University “Kharkiv Aviation Institute”

PhD Student

Department of Aircraft Manufacturing Technology

Artem Suslov, National Aerospace University “Kharkiv Aviation Institute”

PhD Student

Department of Aircraft Manufacturing Technology

Oleksandr Skyba, National Aerospace University “Kharkiv Aviation Institute”

PhD Student

Department of Aircraft Manufacturing Technology

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Devising an approach to prototyping a worn or deformed aviation part based on reverse engineering

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Published

2026-02-27

How to Cite

Maiorova, K., Zaklinskyy, S., Kapinus, O., Suslov, A., & Skyba, O. (2026). Devising an approach to prototyping a worn or deformed aviation part based on reverse engineering. Eastern-European Journal of Enterprise Technologies, 1(1 (139), 96–104. https://doi.org/10.15587/1729-4061.2026.351776

Issue

Vol. 1 No. 1 (139) (2026): Engineering technological systems

Section

Engineering technological systems

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Copyright (c) 2026 Kateryna Maiorova, Sergiy Zaklinskyy, Oleksandra Kapinus, Artem Suslov, Oleksandr Skyba

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