Roshani Chawke 7th August 2025

Reverse engineering is a smart way to modernize existing equipment without reinventing the wheel. At Katalyst Engineering, we help manufacturers upgrade and recreate machines with precision and efficiency. This case study highlights how we supported a construction equipment client by digitally rebuilding their Early Entry Saw Machine SC65, turning limited documentation into a fully functional, production-ready asset—faster, smarter, and with measurable improvements in cost and performance.

Client Requirement Overview

A leading manufacturer in the construction equipment sector partnered with Katalyst Engineering to develop a new generation of their early entry saw machine. The client possessed only partial design files and PDF drawings of an older version of the machine and required:

• Complete CAD models (3D & 2D) of the Early Entry Saw Machine SC65.
• Detailed manufacturing drawings to reintroduce the product to market in a functional and updated form.
• Cost and time-efficient engineering to ensure rapid development without compromising design integrity or quality.

Their goal was to reverse engineer the SC65 saw machine and prepare it for manufacturing, ensuring the machine could meet modern expectations for reliability and efficiency.

Solution Implemented: A Phased, Data-Driven Reverse Engineering Approach

Katalyst Engineering adopted a structured six-phase reverse engineering process, tailored to ensure precision and manufacturability from concept to production.

1. Input Analysis

• Initiated with a detailed study of the machine using available physical parts and reference documentation.
• Compared incoming data with historical drawings and previous product line manuals.

2. Data Collection & CAD Creation

• Conducted on-site inspection and measurements using advanced mechanical measuring instruments.
• Used PTC Creo and SolidWorks to model every component in 3D based on captured data.

3. CAD & Sketch Uploading

• Uploaded and reviewed all 3D CAD files along with dimensionally accurate 2D sketches.
• Ensured compliance with standard tolerances and GD&T requirements.

4. Review & Design Finalization

• Internal reviews ensured that all dimensions, material specifications, and mechanical clearances met functional requirements.
• Design-for-manufacturability (DFM) checks ensured that every part could be easily produced at scale.

5. Manufacturing

• Provided manufacturing-ready files including assembly drawings, exploded views, and annotations.
• Implemented workflow improvements by optimizing part standardization.

6. Delivery

• Delivered the complete machine SC65 in fully operational condition ready for field deployment.
• Ensured the re-engineered product met performance benchmarks and exceeded client expectations.

Tools & Technologies Used

• CAD Software: PTC Creo, SolidWorks
• Documentation: MS Office, PDF Engineering Drawings
• Hardware: Precision mechanical measuring instruments
• Services Linked: Reverse Engineering Services | CAD Modeling

Key Outcomes & Measurable Impact

Improvement in Workflow

Standardization and modular redesign reduced processing and documentation time by 50%, significantly improving delivery timelines.

Accuracy & Compliance

Fully documented and dimensionally verified design ensured manufacturing compliance and reduced rework costs. Using GD&T annotations, every component met industry-specific tolerances.

Cost Savings & Efficiency

By reusing and improving design architecture, Katalyst Engineering helped the client reduce development expenses, achieve faster time-to-market, and enhance overall engineering efficiency.

Why Katalyst Engineering?

This project is a showcase of Katalyst Engineering’s core philosophy: engineering precision meets practical application. Through its reverse engineering capabilities, Katalyst helps manufacturers extend product life cycles, digitize legacy equipment, and innovate without starting from scratch.

Whether it’s reconstructing complex mechanical systems, upgrading aging machinery, or adapting existing models for new markets, Katalyst Engineering provides the expertise, software, and people to turn concepts into working products fast.

Ready to Transform Legacy Machines into High-Performing Assets?

Explore our Reverse Engineering Services or Contact Us today to discover how Katalyst can help your organization reimagine innovation through design accuracy, CAD expertise, and cost-effective manufacturing workflows.