# Methodology for Verification of Geometrically Complex Components Through Reverse Engineering
## 2 Materials and Methods  
The research focused on designing a geometrically complex welding fixture intended for the assembly of a specific cabin structure (front panel). The primary objective was to develop a fixture that would ensure stability and precision during the welding of sheet metal components, minimizing geometric inaccuracies and deformations caused by heat input during the process. The methodological approach emphasized the detailed design of the fixture, which underwent thorough verification and analysis to ensure its effectiveness in real manufacturing conditions. The fixture design was carried out using advanced CAD software tools, considering all factors affecting welding accuracy as well as the specific characteristics of individual cabin components. Following the conceptual design, a verification process was conducted, which included testing and measuring geometric deviations occurring during welding. This research thus aimed to optimize manufacturing processes and eliminate potential errors in geometric parameters, thereby enhancing the overall quality and reliability of the final product. During the assembly of the cabin, which consists of welded complex components, geometric inaccuracies, and deformations arose due to heat input during welding, improper handling of semi-finished products, and material processing errors such as bending and curvature. These inaccuracies affected the final quality and functionality of the cabin, as deviations from dimensional accuracy requirements led to assembly issues or incorrect positioning of components. The solution to this problem was the design of an effective welding fixture that ensured stability and precision during welding, which was verified using reverse engineering. Until now, quality control has mainly relied on visual assessment and manual measurements, which do not provide sufficient accuracy for detecting minor yet critical geometric defects. This situation underscores the necessity for a new, more precise system for monitoring geometric errors during welding. This research was based on a comprehensive methodology that incorporated several key steps and the use of specific technologies and tools to ensure the precision and quality of welding processes:  
1. Identification of the primary issue, which was ensuring geometric accuracy during the welding of cabin sheet metal components. 2. Review of the current state of welding fixtures and verification of geometric parameters. 3. Consideration of the specific geometric shapes of the cabin and the design of a fixture tailored to these components. 4. Development of a geometrically complex welding fixture aimed at minimizing deformations and deviations of components during welding, utilizing Creo PTC software (version 11.0.0.0). 5. Design of a welding fixture prototype incorporating input parameters, including material selection (steel S235 JR-1.0038) and the chosen welding technology (MAG). 6. Manufacturing the fixture with a focus on dimensional accuracy in positioning semi-finished products (locks, engraving). 7. Application of the 3D scanner Kreon ACE-7-30 (Kreon company, Limoges, France) and the PolyWorks Inspector Standard software (version 2022) for data collection,measurement of geometric deviations of welded components (fixture), and analysis against digital reference data. Measurement results were compared with predefined tolerances to assess the fixture's effectiveness in minimizing errors. * Evaluation of results in terms of deviation acceptability within established tolerances, allowing for an objective assessment of the fixture's efficiency. * Presentation of test results and evaluation of the design's performance. * Discussion of potential process improvements and methods for achieving more precise component positioning and optimization of the welding process. * Formulation of conclusions regarding the effectiveness of the proposed welding fixture in optimizing the production process.