Reverse Engineering (RE) is a technique that uses different approaches to obtain characteristic data of a physical object for which no drawings, documentations or computer models are available. This paper presents an experimental approach of reverse engineering for reconstructing the spur gears. 3D CAD model is made using digital image processing (DIP). Gears have been scanned using a single digital camera. The digitized data of spur gears was collected and processed using MATLAB package with Digital image processing (DIP) technique. It is worth mentioning that the accuracy of the modeling process of given piece depends on the number of points that are captured on the work piece surface. This proposed method is the best tool used in reverse engineering because it is faster and more accurate than the method used the coordinate measurement machines (CMMs). To confirm the effectiveness of the proposed method a comparison is madeusing image processing between the first data of spur gears and the data from the manufactured gears. The obtained results indicated that the proposed digital image processing system is an accurate and reliable reverse engineering for reproducing Spur gears using inexpensive equipment.