Crisis Management Days

Reverse engineering in the aviation industry

Andrija Šaban

VVG

Josip Rauker

Tomislav Štengl Lebenger

Keywords: reverse engineering, aviation industry, CAD reconstruction, additive manufacturing technologies, 3D scanning, 3D printing, certification

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Abstract

Reverse engineering represents a key engineering approach in the modern aviation industry, particularly in the fields of maintenance, repair, and the production of high-value replacement parts. Due to the long service life of aircraft, strict regulatory requirements, and high safety standards, there is often a need for the digital reconstruction of existing components for which original technical documentation is unavailable or obsolete. Reverse engineering, when integrated with additive manufacturing technologies, enables the reconstruction and fabrication of a physical replacement part, as well as its analysis and optimization.

This professional paper provides an overview of the fundamental principles of reverse engineering and examines its application in the aviation industry through a case study involving the production of a replacement jet engine turbine blade.

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References

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FAA (2020). Advisory Circular AC 33.15-1: Turbine engine rotor integrity. Federal Aviation Administration.

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