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In this paper, we explore the technical challenges to automatically generate computer‐aided design models of existing vehicle parts using laser range imaging techniques. We propose a complete system that integrates data acquisition and model reconstruction. We discuss methods to resolve the occlusion problem and the associated registration problem. We also present our reconstruction algorithm. This range image‐based, computer‐aided reverse engineering system has a potential for faster model reconstruction over traditional reverse engineering technologies. Finally, we present results derived from the system.

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