This study uses bionics as an enabling methodology to bridge the gap between biology and engineering for generating innovative design and implementation into a methodology to develop novel technologies. The study proposes an innovative product lifecycle management (PLM) methodology framework that uses bionics as a technical discipline, aiming at analysing and revealing the constructional design and working principles of large-scale, human skeletal biological systems in nature. A novel, reverse biomimetics approach presented as the key engineering factor to maintain design and manufacturing anthropomorphic properties necessary for scientists and engineers with associated methods and processes using commercial software for investigating, analysing, and illustrating different stages of product development. The novel reverse engineering methodology addresses the abstraction issues in two-phase, double symmetrical abstraction-specification cycles which have been identified as the most difficult steps in Fayemi’s eight-step framework. The novel methodology uses functional modelling to support analogy categories with pictorial and virtual knowledge transfer from biology to engineering, removing the limitations of the biomimetic processes facing engineering. The study presents comprehensive processes of bionic design and biomimetic modelling, simulation, optimisation and validation techniques necessary for a drug-releasing chewing robot and an anthropometric prosthetic hand.