1, IntroductionIn the die and mould industry, a manufactured part with sculptured surfaces is generally machined by tracing out plaster templates on a copy milling machine. The difficulty encountered with the copy milling method is that physical models are expensive and time-consuming to produce. Dimensional tolerances are also less than satisfactory in most cases. Reverse engineering has recently become an increasingly important design tool in light of the integration of CAD/ CAM systems with the coordinate measuring machine. The basic concept in reverse engineering involves establishing a CAD model from a manufactured part, or else modifying the existing CAD database by digitalisation. The CAD model can then be sent to a CAM system to generate desired cutting paths for NC machining. Typical problems which occur in reverse engineering are a lack of precise control in the created surface model, the difficulty of processing an enormous amount of digitised data and the problems associated with composite surfaces modelling. In this work, a strategy is presented that combines the parameter optimisation method with a surface blending technique to create 3-dimensional models for objects with composite sculptured surfaces.The process methodologies for reverse engineering have received extensive attention [1][2][3][4][5][6][7][8][9][10][11]. Bidanda et al.[1] discussed a broad range of inspection methods that can be used in computer-based reverse engineering systems. Takagi et al. [2] and Hosni and Ferreira [3] described two laserprobe-based measuring systems for acquiring the x, y, z coordinates of multiple points on the part surface. Bradley et al. [4,5] proposed methods for building quadratic and freeform surface models by use of a CMM mounted with a laser scanner. They later applied the above system, combined with an NC path generation algorithm, for quasi-helical tool path generation of arbitrary curved surface models [6]. Other studies related to the integration of reverse engineering, design and manufacture are concerned with car body design [7], complex engine intake-exhaust ports design [8], rotational parts modelling [9], shoe last design and manufacture [10] and spray gun handle and vibratory bowl design [11]. These works presented several realistic applications, demonstrating the feasibility of reverse engineering for shortening the designto-manufacture lead time.An essential step in reverse engineering is the creation of a CAD model for the part to be manufactured. This CAD model and its database is the source for many of the subsequent analyses, e.g. finite element analysis, NC path generation, process planning, etc. A polygon mesh representation of the object surface by connecting two adjacent data points with a line segment is commonly used, but the created drawings are not accurate enough to represent the original part surface, and are not in an engineering drawing format so are not useful in the manufacturing environment. In addition, the database created is extremely large and cannot be manipulated eas...