Day: 14 July 2025

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How Mechanical Engineering and Technology Are Shaping the Future of Mining in Australia

Discover how mechanical engineering, government funding, and digital innovation are driving the future of mining in Australia. Learn how Hamilton By Design leads the change.

Australia’s mining industry is undergoing one of its most significant transformations in decades. At the heart of this change lies the convergence of mechanical engineering innovation, government-backed funding, and cutting-edge technology.

With over $750 million in federal support for metals manufacturing and state-based funding for METS innovation, mechanical engineers are now in a position to redefine how mining operations are designed, maintained, and optimised.

At Hamilton By Design, we are helping clients across the country harness these changes—offering smart mechanical solutions that are efficient, resilient, and future-ready.

Key Opportunities: How Technology is Reshaping Mechanical Engineering in Mining

1. Government Funding is Fueling Innovation

In March 2025, the Australian Government announced a $750 million investment to boost advanced manufacturing and metals production in Australia.

🔗 Backing Our Metals Manufacturers – Federal Government

This funding opens doors for:

  • Prototyping new mechanical assemblies

  • Automation upgrades for existing mining plants

  • Local manufacturing partnerships to reduce supply chain risk

At Hamilton By Design, we are already supporting mining clients to align their capital projects with these funding pathways.

2. Digital Tools Enhance Mechanical Performance

According to the CSIRO METS Roadmap, digitalisation and automation are critical for the next phase of mining growth.

We implement:

  • LiDAR scanning for as-built plant modelling

  • Finite Element Analysis (FEA) for structural design optimisation

  • Predictive maintenance planning using real-time sensor data

These tools not only extend the life of critical components but also enhance safety, reduce downtime, and support remote operations.

3. WA and NSW Governments Are Supporting METS Innovation

The Western Australian government continues to support Mining Equipment, Technology and Services (METS) innovation and commercialisation through its METS Innovation Grants.

🔗 WA METS Innovation Funding

This creates opportunities for mechanical engineering firms to:

  • Collaborate with OEMs and fabricators

  • Introduce novel materials and designs for harsh mining environments

  • Lead the push toward zero-emissions equipment and sustainable design

Hamilton By Design’s agile project delivery and deep mechanical experience allow us to integrate seamlessly with these innovation pipelines.

The Challenges: Bridging the Gap Between Legacy and Future

Despite the exciting momentum, the sector also faces critical challenges:

  • Skills Gaps: Many engineers are not yet equipped with digital or automation skills.

  • System Complexity: Mechanical systems are increasingly integrated with electrical and digital subsystems, requiring multidisciplinary design thinking.

  • Capital Risk: Large investments in automation must deliver measurable value, which requires robust mechanical frameworks.

Hamilton By Design addresses these risks by offering not only high-quality design services, but also strategy, planning, and training support to ensure seamless project delivery.

Why Hamilton By Design is Your Engineering Partner of the Future

We don’t just design parts—we engineer solutions.

Our core services include:

  • Mining mechanical design (transfer chutes, diverter systems, sheet metal)

  • Structural and stress analysis (using FEA and vibration simulation)

  • LiDAR-enabled plant scanning for reverse engineering and documentation

  • Sustainable, future-ready mechanical engineering consultancy

We work with clients across NSW, WA, QLD, and SA, offering nationwide support for design, development, and delivery.

Let’s Engineer the Future Together

Mechanical engineering is no longer just about function—it’s about intelligence, adaptability, and sustainability.

At Hamilton By Design, we help mining companies, fabricators, and OEMs thrive in this new landscape. Whether you’re applying for funding, upgrading equipment, or redesigning your processing infrastructure, we have the tools, experience, and innovation to lead you forward.

🔗 Contact us at www.hamiltonbydesign.com.au

📧 Or get in touch to start a project discussion today.

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Harnessing Opportunity in Australia’s $1.2 B Critical Minerals Push

Australia’s Federal Government has announced an A$1.2 billion Critical Minerals Strategic Reserve, backed by a $1 billion top-up to its existing Critical Minerals Facility. With implementation set for the second half of 2026, the Reserve aims to secure critical minerals—lithium, cobalt, nickel, rare earths—through government offtake agreements and strategic stockpiling miningmonthly.com+15anthonyalbanese.com.au+15discoveryalert.com.au+15.

Why It Matters for Mechanical Engineers

This isn’t just political positioning—it’s a major call to action for mechanical engineering consultancies:

  • Scale and diversification of processing sites – More projects will need robust mechanical systems from crushing and conveying to structural and structural integrity assessments, especially for rare earths and heavy metals.
  • Advanced processing technologies – Selective stockpiling and refining of critical minerals will require high-precision mechanical design, wear management, and optimization of machinery performance.
  • Infrastructure and retrofit demand – The Reserve extends the Critical Minerals Facility’s reach to A$5 billion, catalysing greenfield builds and upgrades—areas where Hamilton By Design excels.

Strategic Insights for Hamilton By Design

At Hamilton By Design, our strength lies in supporting projects from feasibility to commissioning, encompassing:

  • Materials handling systems – conveyors, stockpiles, chutes
  • Structural and fatigue engineering – ensuring safety and longevity under harsh industrial conditions
  • Wear and reliability optimisation – extending lifespan and uptime of mechanical assets
  • Digital tools – such as FEA, 3D scanning, and digital twins to enhance design accuracy and project efficiency

This Government-backed industrial growth is a signal for mining contractors and OEMs to engage expert mechanical consultants early—ensuring streamlined, compliant, and future-proofed system integration.

🛠️ How Hamilton By Design Adds Value

What You GetHow It Helps
Proven materials-handling systems designScalable, reliable conveyors and chutes for critical-mineral plants
End-to-end structural assessmentsEnables compliance with WHS, AS/NZS and long-term asset management
Wear analysis & maintenance planningReduces downtime and extends asset lifespan
Integration of digital engineeringImproves commissioning, reduces risk and cost overruns

With major investments planned and a strong industrial trajectory ahead, now is the time for OEMs and mining clients to tap into specialist mechanical consulting support.

Let’s talk about how Hamilton By Design can partner to deliver cutting‑edge materials handling and structural engineering solutions for your next critical minerals project.

Hamilton By Design | Mechanical Drafting | Structural Drafting | 3-D Lidar Scanning

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Rigid Body Dynamics vs Transient Structural Analysis in Mining

Why Both Matter in Mechanical and Structural Engineering

In the fast-paced and high-stakes environment of the Australian mining industry, reliable engineering design isn’t just a competitive advantage — it’s a necessity. Across regions like the Pilbara, Kalgoorlie, the Hunter Valley, Bowen Basin, and Mount Isa, mining operations depend on complex mechanical systems that must perform under extreme loads, harsh conditions, and round-the-clock operation.

To ensure safety, reliability, and performance, mining engineers increasingly rely on advanced simulation tools like Rigid Body Dynamics (RBD) and Transient Structural Analysis (TSA). While these tools might appear similar, they serve fundamentally different purposes in mechanical and structural engineering. Using the right tool at the right time can dramatically reduce downtime, improve equipment longevity, and lower operating costs.

At Hamilton By Design, we bring the latest in engineering simulation and scanning technology directly to your mining operation — wherever you are in Australia. Whether you’re operating in the iron-rich Pilbara, the gold-rich Kalgoorlie, or deep in Mount Isa’s underground hard rock mines, we deliver world-class engineering solutions on-site or remotely.

What is Transient Structural Analysis?

Transient Structural Analysis (TSA) is a Finite Element Analysis (FEA) technique that models how structures respond to time-varying loads. It provides insights into:

  • Displacement and deformation under dynamic loads
  • Stress and strain distribution over time
  • Vibrations and impact response
  • Fatigue life prediction

This type of simulation is essential when you’re dealing with high-frequency loading, shock events, or long-term structural wear and fatigue. TSA is invaluable for assessing risk in static and semi-dynamic systems across mining sites.

Typical TSA applications in mining include:

  • Vibrating screens and feeder structures
  • Crusher housings and foundations
  • Chutes and hoppers exposed to high-velocity ore impact
  • Structural skids for processing equipment
  • Equipment subject to cyclic fatigue (e.g., slurry pumps, reclaimer arms)

What is Rigid Body Dynamics?

Rigid Body Dynamics (RBD) focuses on the motion of bodies under the assumption they do not deform. This tool models:

  • Position, velocity, and acceleration
  • Reaction forces at joints and actuators
  • Dynamic behaviour of moving parts and linkages
  • Contact, impact, and frictional interaction

Unlike TSA, RBD doesn’t solve for stress or strain. Instead, it calculates the kinematics and kinetics of motion systems — making it ideal for analysing mechanical assemblies where movement, timing, and loads are key.

Common RBD applications in mining include:

  • Stacker-reclaimer arms and boom articulation
  • Mobile equipment with hydraulic or mechanical actuators
  • Diverter chutes and gating systems
  • Rockbreaker arm kinematics
  • Conveyor take-up and tensioning systems

RBD also plays a pivotal role in process optimisation and troubleshooting — helping engineers simulate how mechanisms will respond under load, ensuring operational efficiency before physical prototypes are built.

Why TSA Can’t Replace RBD (and Vice Versa)

While TSA includes rigid body motion as part of the total displacement field, it is not designed for efficient or accurate motion simulation. Trying to model the dynamics of a moving mechanism in TSA can:

  • Lead to slow solve times and high computational cost
  • Produce unstable results due to unconstrained motion
  • Provide limited insight into timing, velocity, or actuation behaviour

Conversely, using RBD for structures that flex, vibrate, or wear over time won’t give you the data needed to assess material failure or fatigue.

The takeaway? Use TSA when deformation matters. Use RBD when motion matters. Use both when you need the complete picture.

Regional Applications Across Australian Mining

Hamilton By Design supports clients across Australia’s mining regions with tailored simulation services designed to meet real operational needs.

⚫ Pilbara – Iron Ore

With high-capacity iron ore operations, this region depends on large-scale materials handling systems.

  • Use RBD to simulate boom movement, slewing systems, and travel paths of stackers.
  • Use TSA to assess fatigue on booms, rail frames, and conveyor supports exposed to cyclic load.

Hamilton By Design helps model these systems efficiently, ensuring both accurate motion control and structural durability. Contact us for help simulating your Pilbara handling systems.

💛 Kalgoorlie – Goldfields (Eastern Gold Region)

Gold operations rely on compact, high-force machinery in confined processing facilities.

  • Use TSA to simulate vibration-induced stress in equipment frames and foundations.
  • Use RBD to model diverter gates, hydraulic arms, and transport carts in processing facilities.

Whether you’re retrofitting a plant or building a new line, Hamilton By Design provides flexible support wherever you operate. Email sales@hamiltonbydesign.com.au to learn more.

⚫ Hunter Valley – Coal (Thermal)

Thermal coal operations in NSW require robust, wear-resistant infrastructure.

  • RBD helps simulate automated diverters, boom stackers, and actuated gates.
  • TSA ensures the wear-prone chutes and hoppers withstand repetitive impacts.

We provide quick-turn simulations for both brownfield and greenfield projects. Get in touch to scope your simulation needs.

⚫ Bowen Basin – Coal (Metallurgical)

Queensland’s met coal operations power the global steel industry.

  • RBD enables accurate simulation of take-up systems and longwall motion.
  • TSA supports design of structural supports under repetitive and impact loading.

Our experts work with surface and underground operators, reducing risk through advanced motion and stress analysis. Request a quote at sales@hamiltonbydesign.com.au.

🔵 Mount Isa – Hard Rock Mining

Mount Isa’s deep and abrasive ore bodies test every piece of equipment.

  • RBD is ideal for simulating rockbreaker motion, loader paths, and mobile assets.
  • TSA provides insights into vibration effects on headframes, bins, and fixed plant.

Hamilton By Design offers full analysis support for operators in remote locations. Contact us today for tailored advice.

When to Use Both Tools Together

A real advantage emerges when RBD and TSA are used in combination:

  • RBD identifies dynamic forces and timing on moving parts
  • TSA then evaluates the structural response to those forces

For example, in a diverter chute:

  1. RBD determines the acceleration profile, impact forces, and system timing.
  2. TSA uses that input to analyse whether the chute will survive years of repeated service.

This integrated approach results in more accurate models, fewer design revisions, and significantly lower project risk.

Why Work with Hamilton By Design?

As mechanical engineering consultants with national reach, Hamilton By Design offers:

  • Combined RBD and TSA simulation capability
  • Lidar scanning and digital plant modelling
  • Experience with mining-specific assets and constraints
  • Mobile, responsive teams that bring technology to you

From site scoping to final design verification, we help our clients solve the right problem, the right way.

Have a project in mind? Reach out via our contact page or email sales@hamiltonbydesign.com.au.

Conclusion: Technology That Moves With You

Rigid Body Dynamics and Transient Structural Analysis are not interchangeable — they are complementary. Each method offers unique insights into how a mining system performs — whether moving, flexing, vibrating, or carrying tonnes of ore.

At Hamilton By Design, we believe engineering technology should move as fast and far as our clients do. That’s why we bring simulation, scanning, and design tools directly to you, wherever you operate across Australia.

If your system moves, simulate it with RBD. If your structure flexes, vibrates, or wears, model it with TSA. For full insight? Use both.

Let us help you design smarter, safer mining systems.

Hamilton By Design – Bringing Engineering Technology to You, Wherever You Are in Australia


www.hamiltonbydesign.com.au/contact-us

Email: sales@hamiltonbydesign.com.au

Hamilton By Design | Mechanical Drafting | Structural Drafting | 3-D Lidar Scanning

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Rigid Body Dynamics vs Transient Structural Analysis in Mining: Why Both Matter in Mechanical and Structural Engineering

Rigid Body Dynamics vs Transient Structural Analysis – How does it apply to the Mining industry?

In the Australian mining industry — where heavy equipment, high-value production, and harsh conditions are the norm — the ability to simulate, test, and validate mechanical systems before they are fabricated or fail in the field is not just beneficial, it’s essential.

From iron ore operations in the Pilbara, to gold mining east of Perth, across to coal in the Hunter Valley and Bowen Basin, and up to hard rock mines in Mount Isa, mining operations rely heavily on engineered systems that move, load, transfer, and endure extreme forces. These systems are increasingly modelled using computer-aided engineering (CAE) tools to improve design accuracy, increase reliability, and reduce downtime.

Two of the most powerful tools in the mechanical and structural engineering toolbox are Rigid Body Dynamics (RBD) and Transient Structural Analysis (TSA). Both play key roles — but they serve very different purposes.

At Hamilton By Design, we help clients across Australia choose and implement the right type of simulation, whether you’re evaluating motion, stress, fatigue, wear, or all of the above.

What is Transient Structural Analysis (TSA)?

Transient Structural Analysis is a finite element-based simulation used to evaluate how a structure deforms under time-dependent loads. It’s used to calculate:

  • Displacement and deformation

  • Internal stresses and strains

  • Vibrations and dynamic response

  • Fatigue or structural failure under repeated loading

TSA is essential for components subjected to impact, vibration, or varying loads over time — all of which are common in mining.

Mining Applications of TSA:

  • Vibrating screens and feeders

  • High-speed chutes or hoppers handling large volumes

  • Crusher housings and rotating equipment supports

  • Structural skids and frames under mobile loads

  • Transfer stations experiencing dynamic load shifts

What is Rigid Body Dynamics (RBD)?

Rigid Body Dynamics is used to simulate the motion of objects under the influence of forces, assuming the bodies themselves do not deform. RBD calculates:

  • Positions, velocities, and accelerations of components

  • Reaction forces at joints and constraints

  • Behaviour of actuators, linkages, and arms

  • Impact and collision between rigid parts

It’s particularly useful for modelling complex mechanisms and moving systems, such as hydraulic rams, rotary actuators, diverter gates, and articulated machinery.

Mining Applications of RBD:

  • Transfer chutes with moving diverter arms

  • Stacker-reclaimers and shiploaders

  • Drill mast articulation and boom operations

  • Hydraulic take-up systems on conveyors

  • Rockbreaker arms and crusher feed assemblies

Why TSA Isn’t a Substitute for RBD

Although TSA includes the ability to simulate rigid body motion as part of the total deformation field, it is not optimised for modelling systems where motion and kinematic behaviour are the primary focus. TSA solvers are geared towards tracking internal stresses, not joint movement or mechanical control.

If you try to use TSA for systems like diverter gates or mobile stackers:

  • The solver becomes slow and resource-heavy

  • You waste time calculating strain in components that are not expected to deform

  • You risk numerical instability if the system has insufficient structural constraints

RBD, on the other hand, is lean, fast, and perfectly suited for motion analysis. It handles joints, constraints, friction, impacts, and actuators efficiently without the complexity of a full finite element model.

Region-Specific Mining Examples

Let’s explore how these principles apply across key Australian mining regions.

🔶 Pilbara (Iron Ore – North of Perth)

In the Pilbara, high-throughput handling systems like stacker-reclaimers, conveyors, and train loadouts dominate. While TSA is critical for verifying the structural integrity of boom supports or transfer station bases, RBD is essential for simulating the precise motion of long booms, rotating car dumpers, and slewing mechanisms — especially when automated systems are involved.

🟡 Kalgoorlie & Goldfields (Gold – East of Perth)

In this region, we often see compact yet high-capacity systems like ball mills, crushers, and slurry pumps. TSA is ideal for evaluating fatigue life, support frame stresses, and dynamic loading from mill vibration. However, diverter systems in process plants or mobile material handling arms often require RBD to evaluate motion paths and ensure smooth operation under hydraulic or pneumatic control.

⚫ Hunter Valley (Thermal Coal)

Bulk handling is central in this region. TSA is used to assess the wear and fatigue life of chutes, hoppers, and vibrating feeders. For moving equipment like stackers, tripper cars, or sampler mechanisms, RBD provides fast, accurate insight into system dynamics, travel time, and constraint loads.

⚫ Bowen Basin (Metallurgical Coal)

Here, systems like longwall supports, draglines, and hydraulic roof supports dominate. RBD plays a crucial role in simulating the interaction between actuators and supports, ensuring control logic matches physical capability. TSA is then applied to determine structural integrity and fatigue under repetitive stress.

🔵 Mount Isa (Hard Rock Mining)

With aggressive ores and complex underground networks, Mount Isa operations demand robust systems. TSA is vital for verifying vibration resistance and structural life of crushers, vibrating screens, and bin supports. But the motion of equipment like rockbreakers, boom arms, and autonomous loaders must be analysed with RBD to ensure precise control and motion under harsh conditions.

Combining Both for Complete Insight

The real power comes when TSA and RBD are used together. For example:

  • Use RBD to simulate the motion of a diverter arm and identify peak reaction forces.

  • Feed those forces into a TSA model to evaluate stress and fatigue in the pivot brackets or mounting plates.

This combination provides full lifecycle analysis — motion, loads, stress, and safety.

Engineering Support from Hamilton By Design

At Hamilton By Design, we understand how to apply these tools to real-world mining problems. We specialise in:

  • Mechanical system simulation and analysis

  • Lidar scanning and digital plant modelling

  • Design for manufacturability and reliability

  • Integrated RBD + TSA solutions tailored to mining

Whether you’re developing a new materials handling system, upgrading an existing structure, or troubleshooting motion-related issues, our team can provide insight-driven solutions that save time and money.

👉 Learn more at www.hamiltonbydesign.com.au or contact us to request a capability statement or project discussion.

Final Thoughts

Rigid Body Dynamics and Transient Structural Analysis aren’t interchangeable — they are complementary. In the demanding environment of the mining industry, knowing when and how to use each tool can make the difference between a reliable plant and one plagued by maintenance issues and inefficiencies.

If your system moves, RBD gives you clarity. If it bends, vibrates, or wears, TSA gives you answers.

Hamilton By Design – Engineering Australia’s Mining Future.


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