Reverse Engineering methods are becoming more and more important in product development processes in cases without CAD models or modified physical objects. For numerical calculations of scanned components, using, for instance, the Finite Element Method (FEM) to look at strength or vibration characteristics, we need the previously scanned data, obtained via Geometric Reverse Engineering, to be converted into CAD surface data, a Finite Element-meshing and a determination of material parameters and constraints. Tremendous effort must be expended in the course of performing repeated Geometric Reverse Engineering and FE-meshing, which must be done when there are iterative, largely local changes in real geometry (such as when incorporating forming dies) or in the case of topologically similar objects, which must be scanned again and again.

This project is aimed at the generation of new calculation models using an appropriate adaption of existing FE meshes (made using a CAD model, for example) or FE meshes previously created with the help of scan data through the retention of intelligent meshing (constraints, material, element type etc.). In terms of their topology, these new meshes should adapt themselves to changes in geometry. Time-consuming Geometric Reverse Engineering, as well as re-meshing, can thus be bypassed. Product development cycles frequently proceed in an iterative manner. Repetition of process steps is intended to improve the product in order to achieve an optimum result in design and dimensioning. The goal of these research activities is to reduce the process steps from 3D scan data to FE-meshing, in particular in development cycles. The paper introduces the project’s concept, its initial results, and further steps.

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