Abstract: The pure copying in reverse engineering (RE) has already been adapted to the developing market no longer. The integration of RE and rapid prototyping (RP) is gradually closed daily with the development of the compute technique. The innovation of RE techniques is required during the process of product’s designing and manufacturing. The synthetical optimization is put forward: the scatter points got after scanning and cicrcularities are triangulated, and the format of stereo lithography file (STL) is created, the 2D optimization is realized with the method of the least right and the method of the least internal angle becoming maximum based on the specialty of the mesh and combined the peculiarity of the circularity partition. The 3D optimization is fulfilled with points adding according to the specialty of the mesh, and then the deformation of the triangles after mapping onto 3D is avoided. With the Boolean operation, the STL format of new product model is formed by arbitrarily the entity’s integration and arbitrarily truncating of entity. The 3D optimization is realized by shape control and other treatments of new product model, therefore, the time and the cost of new product development is reduced.

Key words: Boolean operation, Mesh optimization, Rapid prototyping (RP), Reverse engineering (RE), Stereo lithography file(STL)