The paper describes the innovative solution for revitalization of hydro turbines by using the techniques of reverse engineering and virtual production. The application of modern digital tools in developing, designing and producing shows substantial benefits in improving the existing hydro turbine. Model testing in these cases is not necessary to implement because as the basis is used the known geometry of existing hydro turbine runners and buckets. Digital tools allow a relatively easy way to develop new geometry, improve hydraulic performances of turbines and reach a greater level of usefulness with minimal costs. This paper aims to show optimized geometry and improvement of the Pelton turbine performance using the presented approach