<p>This study presents how to improve reverse engineering processes using the C-K theory of design. First, conventional reverse engineering (which relies on large point clouds of the object to be reverse-engineered obtained through 3D scanning) and its characteristics are studied. Next, the conventional reverse engineering processes are studied using the C-K theory of design, highlighting areas for improvement. Afterward, a new reverse engineering method based on the C-K theory of design is proposed. This method integrates three types of knowledge: creative definitional knowledge, informal inductive knowledge, and deductive knowledge. These types of knowledge facilitate the generation of planner point clouds, capturing important features of the object to be reverse-engineered. These point clouds can be easily converted into a 3D CAD model, supporting digitization and fabrication. The efficacy of the proposed C-K theory-based reverse engineering is demonstrated by reverse engineering a damaged&#xa0;gear-pinion set. Unlike conventional reverse engineering, which mainly focuses on replicating a given object, this new approach takes a different path; it enables the creation of innovative solutions that achieve the same functionality as the original object. This shift from strict replication to creativity is a major advantage. By leveraging this advantage, the proposed reverse engineering method can be applied to (for example) remanufacturing problems, which will be delved into the next phase of this study.</p>