Quality Digest was recently fortunate enough to get more information on Geomagic Design X for reverse engineering from David Mihal, global commercial director of the Geomagic software product line within Hexagon’s Manufacturing Intelligence division. The newly available software converts data from 3D scans into 3D models. In addition to its reverse engineering capabilities, it’s feature-based, affordable, and editable—giving it a competitive edge for companies that need to build custom models efficiently.

Quality Digest: With so many people looking for lean solutions, how would you say reverse engineering capabilities are changing and improving the industry on that front?

David Mihal: As manufacturers push for leaner, more efficient operations, reverse engineering has evolved from a reactive process into a strategic driver of continuous improvement. Geomagic Design X leads this shift by turning 3D scan data into precise, editable CAD models faster than ever, eliminating guesswork, reducing rework, and shortening product development cycles. By enabling teams to rapidly re-create and optimize existing parts or tooling, Design X helps manufacturers cut waste, extend asset life, and accelerate innovation, all core principles of lean manufacturing.

QD: What is reverse mentoring, and how does it decrease the skills gap?

DM: Reverse mentoring pairs younger, tech-savvy employees with experienced professionals to share digital skills and fresh perspectives, accelerating knowledge transfer and innovation. In manufacturing, Geomagic Design X enables this by bridging generational expertise, allowing seasoned engineers to apply their deep design knowledge while younger staff introduce advanced 3D scanning and reverse-engineering workflows. The result is faster upskilling, smoother adoption of digital tools, and a reduced skills gap across teams.

QD: How has digitization affected modern manufacturing processes?

DM: Digitization has transformed manufacturing into a connected, data-driven ecosystem where every stage, from design to production, is optimized through digital tools. Within this landscape, reverse engineering has become a vital bridge between the physical and digital worlds. Using advanced digitization solutions like Geomagic Design X, manufacturers can capture 3D scan data from real parts and convert it into accurate CAD models that integrate seamlessly with downstream processes such as simulation, validation, and additive or subtractive manufacturing. This capability closes the loop between legacy components and modern digital workflows, enabling faster innovation, smarter redesign, and more agile, efficient production.

QD: How do these modern practices affect manufacturing on a large scale within the industry vs. within smaller shops and companies?

DM: On a large scale, digitized reverse engineering allows major manufacturers to accelerate product development, improve quality, and seamlessly integrate legacy components into digital production ecosystems. Geomagic Design X plays a key role by standardizing complex workflows and enabling collaboration across global teams.

Filling in the blanks

Mihal also notes this software’s ability to fill in the blanks for large-scale projects, such as those within the aerospace and defense manufacturing industries.

Geomagic Design X enables engineers to rapidly remanufacture and repair legacy, large-scale components by converting 3D scan data into precise, editable CAD models when original drawings or digital files are missing. Its advanced point-cloud processing, feature recognition, and hybrid surfacing tools allow worn or distorted parts such as castings, airframe structures, and engine components to be digitally reconstructed, validated, and optimized for manufacture or repair. This reduces downtime, restores design intent, extends product life, and builds a digital archive for future maintenance, all while maintaining the precision and traceability required in regulated aerospace environments.

For smaller shops, the entry-level Geomagic Design X Go solution, available by subscription, has made this powerful technology more accessible by removing the high upfront costs that once limited adoption. With the rise of affordable and even free 3D scanning tools such as handheld scanners and photogrammetry apps, reverse engineering is no longer confined to large enterprises.

This democratization of both scanning and software empowers smaller businesses to reproduce, modify, and optimize parts with the same precision as industry leaders. The result is a surge in reverse engineering adoption across all levels of manufacturing, driving leaner operations, faster innovation, and a more connected, digitally fluent industry.