Competitive Analytical Benchmarking

Benchmarking and Competitive Analysis are fundamental ingredients in successful product development.

Optimal provides methodologies for measuring and monitoring key performance characteristics of our customers and relevant competitors’ products and product components.

Our system includes a comprehensive review of design constraints to get optimal results from our measurement and scanning processes. We offer a unique blend of advanced technologies and measurement expertise that provide you with cost effective, rapid solutions.

We can even provide you complete product teardown to a final build book referenced to cataloged parts and more.

Optimal’s comprehensive competitive benchmarking services allow you to answer these critical questions about a product:

Ready to find out more?

Contact us today for more information on our engineering capabilities.


Optimal Specializes in Design and Analytical Benchmarking

Optimal’s Benchmarking, Reverse Engineering, and Metrology Services offer a complete and comprehensive line of dimensional measurement services for 3D scanning, reverse engineering, 3D digitizing, and non-contact inspection. Our 3D Scanners are suitable for almost any dimensional measurement task.


Through our Benchmarking, Scanning, Reverse Engineering, and Engineering Services, you get the availability of product geometry (CAD), structural / flow performance data (FEA / CAE / CFD), and manufacturing processes that will help you improve the following:

  • Perform benchmarking and competitive analysis
  • Quantify competitive threats
  • Improve market position
  • Penetration into new or international markets
  • Reduce product development cost for entirely new product
  • Reducing weight
  • Add new features
  • Make products more robust
  • Increase product reliability
  • Improve time-to-market
  • Reduce manufacturing costs

Some of the deliverables you receive include:

  • CAD Data
  • Inspection Reports
  • Visualization Data
  • Parametric Models
  • Solid Models
  • CAE Models
  • Cut sections
  • Loft Surfaces
  • Surface Analysis
  • Rapid Machining Data

Reverse Engineering

Optimal, Inc. is one of the leading reverse engineering companies providing complete 3D scanning and reverse engineering services to our customers since 1999. Optimal provides full reverse engineering and scan services ranging from 3D laser scanning, rapid prototyping to delivery of a final optimized CAD design solutions, or even CAE models.

Reverse Engineering goes by a lot of names… whether you call it 3D Scanning, Laser Scanning, Digitizing, Rapid Prototyping, or Metrology, you can count on Optimal’s expertise in reverse engineering and digitizing if you need to generate 3D CAD models from the 3D scan of existing objects.

Optimal can provide simple to full engineering services, from scanning to CAE model development, to material evaluation and CAD creation, depending on what you need.

Vehicle Teardown & 3D Scan

How Else Can You Benefit from Reverse Engineering?

There are many possibilities, most of which shorten your development process, improve your design quality, and reduce development and production costs. The following list can give you some more ideas.

Reverse Engineering Services offered by Optimal include:
  • Rapid machining & prototyping
  • Create a CAD model from and old design or part
  • 3D modeling of objects, no matter their size
  • Reconstruction from 3D scanning data, probing, 2D drawings, sketches, etc.
  • Design a new part to fit to a legacy part
  • Design modification from actual objects
  • Vehicle tear-down and CAD reconstruction
  • Surface reconstruction
  • Create benchmarking data and compare designs, even competitor designs
  • Bill of Materials
  • Bill of Process Assembly
  • Perform parametric 3D modeling in generic and native formats
  • Quality inspection and measurement
  • Tool development, or optimizing the manufacturing process
  • Data preparation for digital simulation
  • Virtual manufacturing, simulating the assembly process
  • Hybrid reconstruction
  • Value engineering

Our company’s Reverse Engineering, Scanning, and Metrology services will reduce the product development cycle and enhance your overall product design. The results are higher quality, reduced end product cost, and improved customer satisfaction.

Virtual Model Development

Optimal has developed a unique methodology for converting a physical product into a virtual computer model. It involves a high-quality engineering approach where attention to detail is required in all aspects of the process from tear down, scanning, material testing, FE model development.

There is no other company that can ensure their virtual model of the vehicle matches the real thing like Optimal. This is why our CAE analysis correlates so well with physical test of the same product. Our virtual models are a mirror image of the physical product… whether it be a component or a full vehicle.

Optimal Virtual Model Development

Bill of Materials

What’s in it? What does it look like?

Optimal provides an entire parts catalogue with each tear down which includes a detailed analysis of the product you are benchmarking. All parts are accounted for including the joining methods including all welds, fasteners, rivets, structural adhesives. Each part also receives a comprehensive evaluation of its’ material construction including positive material identification (PMI), hardness and stress strain curve measures.

Optimal’s Bill of Materials Analysis includes a catalogue of each component:

  • Part Photos
  • Part Dimensions
  • Part Weights
  • Part Joining Methods
  • Part Material Testing Data


Vehicle Assembly Bill of Materials

Bill of Process

How was it made?

During teardown of a product, Optimal performs an evaluation of how the product was likely assembled. The “Bill of Process” is reconstructed based on an intelligent assessment of how we envisioned the product was assembled component by component with careful consideration for joining techniques. Examples of Optimal’s Bill of Process Analysis…

BIW Main Assembly Line

Bill of Process - BIW Main Assembly Line

Bill of Process (BoP) for BIW

Bill of Process (BoP)

Engineering Analysis

Why was it designed the way it was?

Optimal is a pioneer in computer aided engineering analysis having established methods for FEA and CFD back in the 1980’s. Optimal has experience in engineering analysis and optimization of every component in a vehicle as well as entire automobiles. For more information on specific engineering analysis that is of interest to you, explore our Computer Aided Engineering Services.

Cost Analysis

What did it cost?

Optimal offers cost estimating services through our strategic partners. Competitive benchmarking projects can include an cost estimate for individual components of a defined bill of materials. Estimates are well constructed based on the cost of materials, labor, machining time, etc., and can include supplier identification (where it can be derived) as well as an accurate account of cost based on that supplier’s geography and corresponding unique labor, material acquisition rates.

Optimal is MMBDC Certified Minority SupplierOptimal is ISO 9001:2008 CertifiedOptimal is ISO 14001:2004 CertifiedOptimal is Ford Q1 Certified

Award Winning Quality Service & Value

Through the application of the latest technology coupled with a highly experienced, trained and efficient staff, Optimal is the Engineering Services provider of choice for many companies. Optimal is the recipient of the Ford Motor Company Technical Silver Partner Award for their CAE Services.

Optimal maintains its ISO-9001:2008, ISO-14001:2004, Ford Q1 certifications, is a certified Minority Supplier, and is a member of the Michigan Minority Business Development Council (MMBDC). Optimal was the recipient of the Ford Motor Company Technical Silver Partner Award for their CAE Services.

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