# Methodology for Verification of Geometrically Complex Components Through Reverse Engineering
## 2 Materials and Methods
### Factors Influencing Geometric Accuracy and Quality  
Deficiencies in technological processes can arise for various reasons, with the most common factors including inappropriate production parameters, material properties, the quality of input semi-finished products, and the influence of external environmental conditions. These errors can lead to a reduction in the quality of final products, affect their mechanical properties, and ultimately cause non-conformities in assembly processes. When processing metal components, particularly sheet metal parts, it is essential to precisely monitor each step of the manufacturing process to minimize deviations and defects that may occur during bending, cutting, or welding. One of the key areas where defects occur is the welding process, as highlighted by the red circles in Figure 4. These defects can arise due to several factors, such as improper  
Figure 3: The graphical representation shows weldment deviations, with green indicating acceptable limits, blue for negative deviations, and red for exceedances, helping to identify areas needing adjustment. Figure 2: Illustration of the measured object and scanning equipment setup for optimal access to the surfaces of the cabin weldment. welding parameters (e.g., incorrect heat settings, inadequate welding speed, or unsuitable filler materials), insufficient control over the welding environment (e.g., drafts or fluctuating ambient temperature), or even operator errors. Such defects can result in issues like warping, cracking, or porosity in the weld, all of which compromise the structural integrity and dimensional accuracy of the welded components. These welding-related deficiencies often require rework or corrections, increasing production time and costs [20,21]. During welding, significant thermal changes take place in the material, leading to the formation of the heat-affected zone (HAZ). This zone is critical because its properties differ from those of the unwelded material due to localized heating and subsequent cooling. Incorrect welding parameter settings, such as welding current or welding speed, can cause undesirable structural changes in the material, resulting in cracking or warping [22]. In the detailed view in Figure 5, the heat-affected zone forms in different locations depending on the welding process, joint type, and applied parameters. This zone is situated near the weld metal itself, where significant microstructural changes occur due to thermal exposure. This phenomenon is particularly critical in thin sheet metals, where excessive heat input can lead to overheating and unwanted deformation after cooling [23]. In the processing of sheet metal components, errors may also arise due to incorrect bending, where improper machine settings or inappropriate tool selection lead to deviations in angles and dimensions. These errors can significantly affect subsequent welding operations, as improperly prepared parts may not fit together precisely, resulting in increased weld gaps and reduced joint strength [24]. Additionally, improper material handling can cause surface defects, which later impact the final quality of the welded joint. As shown in Figure 6, properly bent components are correctly positioned, ensuring precise alignment. The correct bend position guarantees perfect contact between parts, minimizing the occurrence of thermal deformations in the welding area and ensuring high weld quality. Figure 4: The front panel of the cabin showing thermal zones where welding-induced temperature variations cause dimensional deviations. Errors in the Design and Wear of Welding Fixtures and Their Impact on the Accuracy of Component Positioning  
Welding fixtures are devices or tools used to hold and position parts during welding to ensure their correct orientation and alignment. The design of a welding fixture involves various steps and considerations to guarantee precise and efficient welding. Improperly designed or worn-out welding fixtures can cause significant issues affecting the overall quality and accuracy of welds.