In this paper, a series of new techniques are used to optimize typical laser scanning sensor. The integrated prototype is compared with traditional approach to demonstrate the much improved performance. In the research and development, camera calibration is achieved by extracting characteristic points of the laser plane, so that the calibration efficiency is improved significantly. With feedback control of its intensity, the laser is automatically adjusted for different material. A modified algorithm is presented to improve the accuracy of laser stripe extraction. The fusion of data extracted from left and right camera is completed with re-sampling technique. The scanner is integrated with a robot arm and some other machinery for on-line measurement and inspection, which provides a flexible measurement tool for reverse engineering.