Porsche Brake Caliper
From STL Mesh to CAD

This project focuses on the reverse engineering of a high-performance brake caliper from a Porsche sports car, manufactured by Brembo. The objective is not the replication of the scanned geometry, but the reconstruction of a stable and fully parametric CAD model suitable for engineering use.

The starting point consists of high-resolution scan data acquired as a dense STL mesh. The mesh is treated as a geometric reference rather than direct modelling input. Particular attention is given to identifying functional regions, load-bearing features, and critical interfaces, which define the structural logic of the component.

The reconstruction process is driven by interpretation rather than geometric approximation. Key features such as piston housings, mounting interfaces, and fluid channels are analysed and rebuilt using controlled geometry, ensuring dimensional consistency and alignment with engineering intent. A structured curve network is developed to guide surface generation, allowing continuity control across complex transitions. Freeform areas are not blindly fitted to the mesh but reconstructed to achieve stable curvature behaviour and manufacturable surface conditions. Symmetry conditions and repetition patterns are evaluated where applicable, reducing dependency on local scan irregularities and reinforcing the parametric nature of the model. Each feature is defined within a logical framework, enabling future modifications without compromising geometric integrity.

The final output is a fully constrained parametric CAD model, clean and structured, suitable for redesign, performance analysis, inspection workflows, or production-oriented applications.