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Due to the rapid advancements in coordinate measuring systems, data processing software, and additive manufacturing (AM) techniques, it has become possible to create copies of existing models through the reverse engineering (RE) process. However, the lack of precise estimates regarding the accuracy of the RE process—particularly at the measurement, reconstruction, and computer-aided design (CAD) modeling stages—poses significant challenges. Additionally, the assessment of dimensional and geometrical errors during the manufacturing stage using AM techniques limits the practical implementation of product replicas in the industry. This paper provides an estimation of the errors encountered in the RE process and the AM stage of various models. It includes examples of an electrical box, a lampshade for a standing lamp, a cover for a vacuum unit, and a battery cover. The geometry of these models was measured using a GOM Scan 1 (Carl Zeiss AG, Jena, Germany). Following the measurement process, data processing was performed, along with CAD modeling, which involved primitive detection, profile extraction, and auto-surface methods using Siemens NX 2406 software (Siemens Digital Industries, Plano, TX, USA). The models were produced using a Fortus 360-mc 3D printer (Stratasys, Eden Prairie, MN, USA) with ABS-M30 material. After fabrication, the models were scanned using a GOM Scan 1 scanner to identify any manufacturing errors. The research findings indicated that overall, 95% of the points representing reconstruction errors are within the maximum deviation range of ±0.6 mm to ±1 mm. The highest errors in CAD modeling were attributed to the auto-surfacing method, overall, 95% of the points are within the average range of ±0.9 mm. In contrast, the lowest errors occurred with the detect primitives method, averaging ±0.6 mm. Overall, 95% of the points representing the surface of a model made using the additive manufacturing technology fall within the deviation range ±0.2 mm on average. The findings provide crucial insights for designers utilizing RE and AM techniques in creating functional model replicas.
