Reverse Engineering – Understanding the Existing, Enabling Innovation

Whether it is obsolete components without documentation, defective parts, or the need to further develop existing systems – reverse engineering provides the solution. Through precise analysis and digital reconstruction of existing products, we create the foundation for reproduction, optimization, or innovation. Using state-of-the-art measurement technology and deep technical expertise, we make the invisible visible – efficiently, accurately, and with a focus on the future.

Reverse engineering in detail:

1. Definition of objectives and analysis of the current state

Objectives of reverse engineering:

  • Understanding the functionality
  • Enabling spare parts or reproduction
  • Identifying optimization potential

Documentation of the original product:

  • Manufacturer information, serial number
  • Existing technical data sheets and specifications
  • Application area and environmental conditions

2. Disassembly and physical analysis

External inspection:

  • Material analysis (e.g., housing, connections)
  • Dimensions and geometry
  • Testing and definition of current sensitivity via correlation

Disassembly of the sensor:

  • Careful opening without damage, if possible
  • Identification of components (reed contact, wiring)

Material tests:

  • Housing material
  • Testing of cable material
  • Testing of connector information, if required

3. Reproduction or optimization

Creation of 3D models and technical drawings:

  • CAD models of the sensor and its components

Material selection for reproduction:

  • Selection of alternative materials if original materials are unavailable

Production of a prototype:

  • Prototype manufacturing and functional tests

Optimization opportunities:

  • Improvements in material, performance, or design

4. Testing and validation

Comparison with the original sensor:

  • Checking measurement data and sensitivity against the original sensor

Certifications and compliances:

  • Ensuring that the reproduced sensor complies with relevant standards (e.g., RoHS, REACH)

5. Final report and documentation

Reverse engineering results:

  • Technical specifications
  • Measurement data and analyses
  • Drawings

Archiving of documentation:

  • Saving all results in a structured manner