Algorithmic model for digital reconstruction of rotational mechanical components based on 3D scanning

Abstract

The accelerated development of digital technologies, particularly 3D scanning techniques combined with reverse engineering procedures, has enabled efficient digital reconstruction of mechanical components in situations where original technical documentation is unavailable or the component has been damaged during service life. This study presents an algorithm-based model developed for the reconstruction of a symmetrical rotational mechanical component using optical 3D scanning and advanced point cloud processing in Geomagic Design X software. The proposed model addresses three characteristic preservation states of the component: a partially damaged part with locally cracked geometry, a completely damaged part with missing geometric segments, and an undamaged reference part. The reconstruction workflow is based on the definition of reference regions, symmetry axis identification, and sectional plane extraction, enabling reliable geometric reconstruction even under conditions of incomplete scanned data. Reconstruction accuracy was evaluated by comparing the generated CAD models with corresponding reference point clouds using deviation color maps and cross-sectional visual analysis. The obtained results indicate that the dominant surface deviations between reconstructed CAD models and scanned data remained within a narrow tolerance range of approximately ±0.1 mm, while statistical deviation analysis confirmed the stability and repeatability of the proposed reconstruction approach. The findings confirm that the developed model represents an efficient, stable, and repeatable method for digital reconstruction of rotational mechanical components with varying degrees of damage