When performing reverse engineering (RE) operations, large volumes of point cloud data may be collected, which are subsequently transformed into surface models using sophisticated RE modeling tools. However, for mechanical components, much extraneous data is collected, which is reduced to curves and surfaces that do not capture design intent. A data acquisition and modeling reconstruction methodology, which combines design and inspection approaches, has been developed to address these issues. Feature types and relationships are identified to formulate a representative 'construction' history tree to assist developing a relevant data collection strategy. The goal is to develop a model reconstruction plan so that a structurally idealized, editable CAD model can be created using standard geometry creation tools. The goal is to quickly develop a reversed engineered CAD model which contains form-function design intent and can be readily modified due to new design and manufacturing constraints. Case studies are presented to highlight the merits of this approach.