Nowadays in many cases of product shape modification where no original design drawing is available, equipments like coordinate measuring machine and rapid prototyping machine are very often employed, together with modification software, to attain integrated technology for product shape modification in a relatively short period of time. This study conducts the measurement of the outer shape of existing complex model and puts it through different steps such as data points acquisition, surface filling, and surface fitting. As the collision testing of physical object is not available, CAE software ANSYS Workbench is therefore used for contact analysis to determine the area of stress concentration after the collision for consequent modification of the shape. Contact analyses before and after the modification are then compared. In the last step, the modified geometric shape is used by the rapid prototyping machine to produce a product prototype for the manufacturer to display. This modification procedure can be widely applied in car manufacturing industry, mobile phone industry, product form design related industry, and so on.
