Objects with complex geometric features find challenges in their computer aided design (CAD) model creation and fabrication. Reverse engineering is a technology used to create the CAD model of the physical objects with complex geometry while CNC machining can be used to manufacture the object by giving proper cutter path. The aim of the paper is to integrate reverse engineering with CNC machining so that objects with complex geometry can be manufactured conveniently. An object (ultrasonic horn) having geometric features like planer surfaces, curved surfaces, slots etc. has been taken to demonstrate it. Further, deviation in the fabricated object from the original object has been computed and maximum deviation is found to be only 3%.

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