The thesis work explores the synergy between Reverse Engineering (RE) and High Pressure Die Casting (HPDC) simulation of a gearbox housing of an electric vehicle. The goal of the research activity is to show the advantages of Computer Aided Engineering (CAE) and to demonstrate how it can be used in Automotive industry to reverse engineer the already existing parts. The 3D Computer Aided (CAD) model obtained through RE is used to perform the casting simulation to optimise the overall manufacturing process. The real part is scanned using FreeScan Combo, a handheld scanner developed by Shining 3D. The 3D point cloud data is then post processed in Geomagic Design X to obtain the 3D CAD model which can be used for further optimisation in terms of manufacturing cost, time, and material requirement.