Reverse engineering (RE) is a pivotal process for replicating and enhancing existing objects, and its integration with additive manufacturing (AM) holds immense potential for advancing manufacturing capabilities. Several data acquisition systems were currently available, and most of them were costly and less efficient. Photogrammetry is one of the techniques of data acquisition systems that uses sequences of photographic images of physical objects for digital modeling through various reconstruction algorithms. The paper presents a design aimed at enhancing the photogrammetry system by developing a low-cost data acquisition device setup for the production of intricate structures through AM. The setup involves a comprehensive approach that combines with a cutting-edge data acquisition system. The system employs the data acquisition system to capture detailed geometric information about complex structures, ensuring precise digital representation. In order to bridge the gap between digital models and physical prototypes, the paper introduced an innovative strategy for data acquisition. This strategy involves developing a line-follower robot that operates around a physical object for data capture. The optimization process focuses on achieving a balance between resolution, speed, and the weight of the data-capturing device. The design of the data acquisition setup prioritized ease of operation and affordability. The captured data was further processed using various post-processing methods and computer-aided RE techniques to generate digital data that can be used for AM. The entire setup is a cost-effective solution for RE, which can replace costly 3D scanners for data acquisition. It can be useful for designers, RE experts, and industries that rely on RE in manufacturing operations.