How to Use SolidWorks for Reverse Engineering: Step-by-Step Guide

To use SolidWorks for reverse engineering, first import your scanned 3D data (like STL or OBJ files) into SolidWorks. Then use tools like ScanTo3D to convert mesh data into surfaces or solids, and refine the model with features such as Surface Modeling and Feature Recognition.

Syntax

Reverse engineering in SolidWorks involves these main steps:

• Import Scan Data: Load 3D scan files (STL, OBJ) using File > Open.
• ScanTo3D Add-in: Activate this add-in to work with mesh and point cloud data.
• Convert Mesh to Surface: Use Surface Wizard or Mesh Prep Wizard to create surfaces from mesh.
• Create Solid Model: Use Surface Knit and Thicken to convert surfaces into solids.
• Feature Recognition: Use FeatureWorks to identify features like holes and bosses for easier editing.

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File > Open > Select STL/OBJ file
Tools > Add-Ins > Activate ScanTo3D
Insert > Surface > Surface Wizard
Insert > Surface > Knit Surface
Insert > Boss/Base > Thicken
Tools > FeatureWorks > Recognize Features

Example

This example shows how to import a scanned STL file and convert it into a solid model:

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1. Open SolidWorks.
2. Go to File > Open and select your scanned STL file.
3. Enable the ScanTo3D add-in via Tools > Add-Ins.
4. Use Insert > Surface > Surface Wizard to create surfaces from the mesh.
5. Use Insert > Surface > Knit Surface to join surfaces.
6. Use Insert > Boss/Base > Thicken to convert the surface into a solid.
7. Use Tools > FeatureWorks > Recognize Features to identify editable features.

Output

A solid 3D model created from the scanned mesh, ready for editing and manufacturing.

Common Pitfalls

• Ignoring mesh quality: Low-quality scans cause poor surface creation. Always clean and simplify mesh before import.
• Skipping add-in activation: Forgetting to enable ScanTo3D prevents mesh tools from working.
• Not knitting surfaces: Surfaces must be knitted before thickening to form solids.
• Overlooking feature recognition: Without FeatureWorks, editing features is difficult and time-consuming.

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Wrong way:
1. Import STL
2. Try to edit mesh directly without ScanTo3D

Right way:
1. Import STL
2. Activate ScanTo3D
3. Convert mesh to surfaces
4. Knit surfaces
5. Thicken to solid
6. Use FeatureWorks

Quick Reference

Step	Action	Purpose
1	Import STL/OBJ file	Load scanned 3D data into SolidWorks
2	Activate ScanTo3D add-in	Enable mesh and point cloud tools
3	Use Surface Wizard	Convert mesh to surfaces
4	Knit surfaces	Join surfaces into one body
5	Thicken surfaces	Create solid model from surfaces
6	FeatureWorks recognition	Identify editable features for design

Key Takeaways

Always activate the ScanTo3D add-in to work with scanned mesh data.

Convert mesh files into surfaces before creating solid models.

Use FeatureWorks to recognize and edit features easily.

Clean and prepare scan data to improve model quality.

Knit surfaces properly before thickening to avoid errors.