Redesign a Part with no available data?

Laser scan the existing part

The existing part was scanned by Sicam. The part was translucent polycarbonite, so it needed to be painted flat white to obtain a good laser scan.

Create smart CAD data.

The scan data was converted to smart CAD data, meaning the CAD model was not composed of extracted splines but was made with fits to basic arcs, lines and circles and included the proper draft angles. This preserved the original design intent and made the data usable for the next step.

Modify CAD data with the new features.

Next, the CAD model was modified to include the new features; the initial goal of the project.

Create an SLA model to verify the design.

Finally, to prove out the new design, Sicam created a SLA model of the part. The new part fit perfectly to the existing mating part and also verified the new design.