Engineering & Product Design
From a napkin sketch or a physical part to a production-ready CAD model. Rev1 Technologies designs, reverse-engineers, and refines parts and products — parametric CAD, scan-to-CAD, design-for-manufacture, and simulation-driven design under one roof.
Based in Auburn Hills, Michigan, serving Michigan, Ohio, and Indiana and working with teams nationwide. We design the way we build — with manufacturing and inspection in the same building, so the model you get is one we can actually scan, prototype, and make.
Have something to design? Let's scope it.
Send us a sketch, a spec, a physical part, or a rough model — with what it needs to do and how it'll be made — and we'll come back with a design approach, scope, and timeline, usually within one business day.
Parametric CAD built to be changed — and built to be made.
We model parts and assemblies in clean, fully parametric CAD, so a dimension change ripples through the whole design instead of breaking it. Every model is built with intent: proper feature trees, controlled tolerances, and geometry chosen for the process that will make it.
- Parametric part & assembly modeling — robust feature trees you can actually edit later.
- Production drawings & GD&T — dimensioned prints your shop or ours can build to.
- Native & neutral files — STEP, IGES, and the formats your suppliers need.
Design services — from first concept to production files.
Engage us for a single CAD model or a full design program. Each capability stands on its own and feeds the next as a part moves from idea to something you can make.
Parametric CAD modeling
Clean, editable part and assembly models built with intent.
- Part & assembly design
- Feature-tree discipline
- STEP / IGES / native output
Reverse engineering
3D scan a physical part and rebuild it as parametric CAD.
- Geomagic Design X workflow
- Scan → solid / surface model
- Legacy & obsolete parts
Design for manufacture
Designs shaped by how they'll actually be made.
- Manufacturability review
- Material & process selection
- Tolerance & cost tuning
Simulation-driven design
Use analysis to shape the geometry, not just check it.
- Ansys-informed design
- Load paths & lightweighting
- Feeds deep FEA / CFD
Product & industrial design
Form, ergonomics, and function that work together.
- Concept & form development
- Ergonomics & usability
- Enclosures & assemblies
Design optimization & revisions
Refine, lightweight, and cost-reduce an existing design.
- Redesign for cost or weight
- Consolidate parts & fasteners
- Revision & drawing control
Turn a physical part back into editable CAD.
No drawings? No native model? We 3D-scan the physical part with our metrology-grade scanners and rebuild it as clean, parametric CAD in Geomagic Design X — capturing real design intent, not just a frozen mesh. Perfect for legacy parts, obsolete components, and hand-modified prototypes. It pairs directly with our 3D scanning & metrology service.
- Scan to solid model — parametric features you can dimension and edit, not a dead mesh.
- Geomagic Design X — the industry scan-to-CAD toolchain, run by people who sell and use it daily.
- Legacy & obsolete parts — recreate components with no surviving drawings or supplier.
We scan, design, prototype, and make — so the model actually works.
We scan, design, simulate, prototype, and manufacture in the same building — so the CAD we hand you is one we can actually build, not a model that dies at the shop door.
Rev1 sells and supports Geomagic, Ansys, and metrology hardware — so reverse engineering and simulation-driven design are run by people who train others on the exact software.
Because we make parts too, DFM isn't a checkbox — every design is shaped by the process, tolerances, and cost of actually producing it.
Metrology-grade 3D scanning feeds our reverse engineering and validation, so models match the real world, not an assumption.
NDAs are standard. Your concepts, CAD, drawings, and product designs stay yours.
Auburn Hills, Michigan — close to Michigan, Ohio, and Indiana teams, and working with clients nationwide.
Understand → Model → Validate → Handoff.
Understand
We start with your intent, constraints, and how the part is made and used — from a sketch, a spec, or a physical sample to scan.
Model
We build clean, parametric CAD — or reverse-engineer a scan into editable geometry — with manufacturability in mind from the first feature.
Validate
We pressure-test the design with DFM review and simulation-driven checks, refining geometry before anything gets cut or molded.
Handoff
You get production-ready models, drawings, and neutral files — and, if you want, a direct path into our prototyping and manufacturing.
Designed around how it will actually be made.
A beautiful model that can't be built is a liability. We design with the process in mind from the start — wall thickness for molding, tool access for machining, orientation for printing — and we tune tolerances so they're tight where it matters and open where it doesn't. When you're ready to build, the design feeds straight into our manufacturing & prototyping service.
- Process-aware geometry — shaped for additive, CNC, casting, or molding from the outset.
- Tolerance & cost tuning — realistic specs the chosen process can actually hit.
- Part & fastener reduction — consolidate features to cut cost and assembly time.
Design work for demanding industries.
Automotive & mobility
Component and fixture design, reverse engineering of legacy parts, and lightweighting for parts that live with heat and vibration.
Aerospace & defense
Tight-tolerance component design, scan-to-CAD of existing hardware, and simulation-informed geometry where fit and margin matter.
Medical & dental
Device and housing design, ergonomic form, and accurate models where finish and iteration speed count.
Industrial & automation
Machine parts, custom tooling and fixtures, and redesigns that cut cost or weight on the production floor.
Consumer products
Product and industrial design — form, ergonomics, and enclosures — carried through to production-ready CAD.
Energy & equipment
Durable component design and reverse engineering for parts that face real load, wear, and environments.
Let the physics shape the geometry.
Analysis shouldn't just grade a finished design — it should drive it. We use Ansys-informed simulation early to see load paths, remove material where it isn't working, and add it where it is. For deep, standalone structural, thermal, or flow studies, we hand off to our dedicated simulation & engineering analysis service (FEA / CFD).
- Design-stage analysis — Ansys-informed checks that steer geometry, not just approve it.
- Lightweighting & load paths — put material where the physics wants it and cut the rest.
- Deep studies on tap — escalate to full FEA / CFD via our simulation service when needed.
Design it once — design it to be made.
Skip the redesign loop that happens when the model meets the shop floor. Bring us the concept or the part and we'll hand back CAD that's ready to prototype and produce.
Form and function, designed together.
The best products feel obvious to use and are still manufacturable. We develop concepts, form, and ergonomics alongside the engineering — so the enclosure, the grip, the interface, and the internals all resolve into one coherent product that looks right and builds right.
- Concept & form development — explore directions before committing to production geometry.
- Ergonomics & usability — design around the hand, the eye, and the task.
- Enclosures & assemblies — housings and mechanisms designed to be assembled and serviced.
A sample of the design problems we solve.
Representative examples across the industries we serve. Details are genericized to protect client confidentiality.
Enclosure redesign around existing electronics
An industrial-automation client needed a housing rebuilt around an existing control board with no current CAD. We scanned the assembly, reverse-engineered the board footprint and mounting into parametric CAD, and delivered a DFM-clean enclosure ready for low-volume production.
Legacy component recreated from a physical part
An aerospace team had an obsolete component with no drawings and no supplier. We 3D-scanned the part, rebuilt it as a tolerance-controlled parametric model in Geomagic Design X, validated the fit against the scan, and handed off production-ready files.
Engineering & product design — common questions.
What does your engineering & design service cover?
Parametric CAD modeling, reverse engineering (3D scan to CAD), design-for-manufacture, simulation-driven design, and product and industrial design. We take a part or product from concept, sketch, spec, or physical sample all the way to production-ready CAD and drawings.
What is reverse engineering, and when do I need it?
Reverse engineering turns a physical part back into editable CAD. We 3D-scan the part and rebuild it as a parametric model in Geomagic Design X, capturing design intent rather than a frozen mesh. It's ideal for legacy or obsolete parts, hand-modified prototypes, or components with no surviving drawings.
What CAD formats do you deliver?
We deliver native models plus neutral files such as STEP and IGES, along with dimensioned production drawings with GD&T where needed. Tell us the formats your suppliers or internal team use and we'll match them.
How is this different from your simulation service?
This service uses analysis at the design stage to shape geometry — Ansys-informed checks that steer the model. For deep, standalone structural, thermal, or flow studies, we hand off to our dedicated simulation and engineering analysis service (FEA / CFD).
Can you also make the parts you design?
Yes. Design is shaped by manufacturability, and the CAD feeds directly into our manufacturing and prototyping service — additive, CNC, urethane casting, and low-volume runs — so one team takes you from concept to real parts.
What do you need to start a design project?
Whatever you have: a sketch, a written spec, a rough model, a competitor reference, or a physical part to scan — plus what it needs to do and how it will be made. If you're unsure, send what you have and we'll help define the rest.
Do you really know Geomagic and Ansys, or just use them?
Both. Rev1 sells and supports metrology hardware and design software including Geomagic and Ansys, so our reverse engineering and simulation-driven design are run by people who train others on the exact tools.
Where are you located and who do you serve?
We're in Auburn Hills, Michigan, serving customers across Michigan, Ohio, and Indiana and working with teams nationwide. NDAs are standard, so your concepts, CAD, and product designs stay confidential.
For immediate assistance:
(248) 707-2950
For immediate assistance:
…