Reverse Engineering and Additive Manufacturing Metrological Evaluation for Sustainable Digitalization in Shipyard Environments

This work presents an experimental validation of a reverse engineering workflow applied to shipyard mechanical components, combining 3D optical scanning and additive manufacturing. The study aimed to assess the capability of the scanning system to accurately reproduce the dimensions of a mechanical manufact, evaluating the effect of the surface conditions. A structured test campaign was developed, starting with a familiarization phase using reference metrological blocks and progressing to the design and production of a multifunctional component, fabricated in both PLA (via Fused Filament Fabrication) and metal (via traditional machining). Scans were performed using portable structured-light and lasergrid assisted 3D scanners, with data processed through proprietary and open-source software. The reconstructed geometries were evaluated through mesh analysis, crosssoftware comparison, and dimensional verification. Results highlight the limitations of automated scanning settings in realworld conditions and the necessity of customized acquisition protocols. The study demonstrates how reverse engineering, supported by additive validation, can serve as a sustainable and flexible metrological tool for shipyard applications, enabling the digitalization of complex components under realistic constraints.