Author: Team - Hamilton By Design

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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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Shaping the Future of Mining : Mechanical Engineering & 3D Lidar Scanning in Mount Isa

 Mechanical Engineering & 3D Lidar Scanning in Mount Isa

Posted by Hamilton By Design | Based in Mount Isa | www.hamiltonbydesign.com.au

🔧 Precision Engineering Meets Digital Innovation in the Mining Sector

In the heart of Australia’s mining country—Mount Isa—Hamilton By Design is delivering cutting-edge mechanical engineering solutions powered by 3D Lidar scanning and point cloud modelling.

Whether you’re managing underground infrastructure, fixed plant upgrades, or brownfield expansions, our advanced tools and design expertise help you visualise, optimise, and execute projects with clarity and confidence.

🏗️ How We Support the Mining Industry

As mechanical engineering consultants, we provide services that reduce project risk, increase design accuracy, and streamline construction workflows. Key areas include:

  • Lidar 3D Scanning of existing plant, pipework, and underground assets

  • Point Cloud Creation for clash detection and design validation

  • Mechanical & Structural Drafting using accurate site data

  • Reverse Engineering of legacy plant or undocumented assets

  • Detailed Design for Modifications & Upgrades

  • Compliance, Auditing, and Risk Reduction

By combining field-tested mechanical engineering with cutting-edge digital capture, we help mining teams make better decisions—faster.

📍 Why Mount Isa?

Mount Isa is home to some of Australia’s largest and most complex mining operations. From Glencore’s copper and zinc mines to contracting hubs servicing the broader North West Minerals Province, this region demands precision, speed, and deep mining knowledge.

Hamilton By Design is based locally in Mount Isa, giving us the unique advantage of rapid site access, practical experience in mining environments, and a strong understanding of local challenges.

📐 Why Use Lidar & Point Clouds?

Lidar scanning has transformed how we approach engineering projects in mining:

  • ✅ Capture complex environments in minutes, not days

  • ✅ Generate ultra-accurate point clouds for design, measurement, and planning

  • ✅ Minimise rework by designing to exact, as-built geometry

  • ✅ Visualise site constraints in 3D before committing to fabrication or install

  • ✅ Integrate scan data with CAD models for seamless design workflows

From underground crushers to surface pipe racks, our Lidar system captures the details—so you can design with certainty.

💡 Use Cases in Mining Projects

Some real-world examples of how we apply mechanical engineering + Lidar scanning in mining:

  • 🏭 Scanning underground pump stations for upgrade design

  • 🔩 Reverse-engineering chutes and hoppers with no existing drawings

  • 🚧 Capturing point clouds of processing plants for structural fit-out

  • ⚙️ Laser-accurate data for mobile plant modifications and safety guarding

  • 📏 Converting scan data into fabrication-ready models and drawings

Want to see a sample point cloud or project output? Just reach out through our website below.

👷 Who We Work With

  • Mining Operators & Engineers

  • Shutdown Coordinators

  • Project Managers & Fabricators

  • EPCM Contractors

  • Surveyors & Design Teams

If you’re responsible for delivering accurate, efficient, and safe mechanical solutions on site—Hamilton By Design is your local partner.

📞 Let’s Talk About Your Next Project

📍 Based in Mount Isa, QLD

🌐 Website: www.hamiltonbydesign.com.au

📧 Email: info@hamiltonbydesign.com.au

Whether you’re planning a brownfield expansion or simply need a scan-to-CAD model of your plant, we’re here to help—on site and on time.

#MountIsaMining #MechanicalEngineering #3DLidar #PointClouds #ScanToCAD #MiningInnovation #PlantDesign #HamiltonByDesign #EngineeringMountIsa #MiningDrafting

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How Mechanical Engineers Are Powering Mining on the Central Coast

The Central Coast of New South Wales is more than just pristine beaches and a relaxed lifestyle. Beneath its surface lies a strong industrial and mining support sector where mechanical engineers are playing a vital role in modernising, maintaining, and innovating heavy machinery and infrastructure.

At Hamilton By Design, we specialise in mechanical engineering consulting services across Australia—including support for clients right here on the Central Coast. Visit us at 👉 www.hamiltonbydesign.com.au to explore our services.

👷 Why Mechanical Engineering Matters in Mining

Mechanical engineers are the invisible backbone of mining operations. In Central Coast-based support industries and nearby projects like Wallarah 2, mechanical engineers handle:

  • Design & Drafting of Mining Infrastructure

  • Maintenance Systems for Plant and Equipment

  • Automation, Robotics, and Sensor Integration

  • Environmental Engineering for Emission Reduction

  • Reliability and Safety Auditing

Whether it’s conveyor systems, processing plants, underground ventilation, or mobile plant maintenance, mechanical engineers ensure it all runs smoothly, safely, and efficiently.

📍 Mechanical Engineering Jobs on the Central Coast

The Central Coast is home to a growing number of engineering-based businesses and industrial hubs:

  • Somersby, Tuggerah, and Lisarow host major mechanical and fabrication workshops.

  • Companies like Wabtec, Coffey, and Boral regularly seek mechanical engineers.

  • The region supports jobs ranging from drafting and design to hands-on site-based maintenance.

At Hamilton By Design, we provide the expertise and consulting support these businesses need—structural drafting, 3D laser scanning, plant design, and more.

👉 Want to collaborate? Visit us at www.hamiltonbydesign.com.au

🔧 Trends Shaping Mechanical Engineering in Mining

If you’re working in, or supplying to, the mining industry, here are five key trends affecting mechanical engineers today:

  1. Automation & Remote Control Systems

  2. Data-Driven Predictive Maintenance

  3. Sustainable Design and Energy Efficiency

  4. Digitisation via Lidar & 3D Scan Models

  5. Multi-disciplinary Integration (Mech + Elec + Struct)

Hamilton By Design helps clients stay ahead of these trends with cutting-edge tools, qualified engineering support, and experienced consultants.

🧑‍🏭 Training Pathways for Engineers on the Coast

  • TAFE NSW offers mechanical engineering and drafting training.

  • Central Coast Council and local employers provide apprenticeships and work experience.

  • Many local high schools and programs now promote STEM and engineering career pathways.

Are you a contractor, project manager, or engineering lead on the Coast looking for expert support? We’re ready to help.

👉 Contact us at www.hamiltonbydesign.com.au

🌊 Why Base Yourself on the Central Coast?

  • Easy access to Newcastle and Sydney mining regions

  • Affordable living and coastal lifestyle

  • Thriving local industry with national project links

Whether you’re managing a plant upgrade or need detailed mechanical drawings for a site modification, Hamilton By Design has the skills and tools to support your project.

📞 Let’s Talk Engineering

Hamilton By Design is a trusted name in mechanical and structural design, offering:

✅ Mechanical design & consulting
✅ Structural drafting
✅ Lidar scanning & 3D modelling
✅ Australia-wide service reach

Visit: www.hamiltonbydesign.com.au
Email: info@hamiltonbydesign.com.au

Your Central Coast Engineering Partner – Hamilton By Design


Supporting Australian mining and industry with precision and experience.

#CentralCoast #MechanicalEngineering #MiningSupport #HamiltonByDesign #EngineeringConsultants #MiningInnovation #NSWIndustry #LidarScanning #PlantDesign

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Why 3D Laser Scanning Might Be the Best Thing You Haven’t Tried Yet

In the world of building, maintaining, and improving anything physical — from mining sites to machinery and industrial plants — accuracy isn’t a bonus; it’s essential.

That’s where 3D laser scanning comes in. And if you haven’t explored how it works (or how easy it is to use), it’s worth taking a moment to learn how Hamilton By Design is using it to help companies all over Australia.

Visit the full page here: Hamilton By Design – 3D Laser Scanning


What Is 3D Laser Scanning – and Why Should You Care?

Imagine being able to get an exact digital version of a building, a plant room, or even a set of steel structures — all without needing to stop production or bring in tape measures and ladders. That’s what 3D laser scanning does.

Using advanced scanning equipment, we can capture every detail of a structure or environment and turn it into a highly accurate digital model. No guesswork. No rework. No surprises.

Think of it like Google Street View — but for your machinery, plant, or site.




Who Uses It – And What For?

At Hamilton By Design, we work with clients across the country in industries like:

  • Mining and minerals

  • Heavy industry

  • Construction and engineering

  • Manufacturing

  • Energy and infrastructure

They use 3D scans for things like:

  • Upgrading plant rooms without taking things apart first

  • Modifying equipment without clashing into existing structures

  • Creating “as-built” records of facilities for safety and compliance

  • Planning shutdowns with fewer risks and unknowns

Whether you’re fixing, building, or upgrading, scanning gives you a smarter way to plan.

The Real Value: Less Downtime, More Certainty

One of the biggest wins our clients see is speed. A scan that takes a day can save weeks of redesigns, measurement errors, or clashes down the track.

We’ve scanned conveyor systems, CHPP facilities, tank farms, processing equipment, and even confined spaces — all while the client kept working. The result? Better decisions, cleaner installs, and safer planning.

What Happens After the Scan?

After the scanning is complete, we deliver a digital 3D model of your asset. You can use this model to:

  • Design upgrades

  • Check clearances

  • Add new equipment into the space

  • Or just have a clean, accurate reference for future work

Our team also provides 3D CAD modelling, so if you want a fully engineered solution — not just the scan — we can help turn the model into your next design.

We’re Local — But We Work Nationally

With offices and scanners based in Perth, Brisbane, Central Coast, Mount Isa, and Melbourne, we’re never too far from where you are. And we work with all sorts of clients — from large mine operators to local manufacturers.

Our flexibility is what clients value most — whether it’s a one-day site visit or an ongoing partnership.

Why Hamilton By Design?

We’re not just a scanning company. We’re mechanical design engineers who know what comes after the scan. That means your data isn’t just collected — it’s actually useful, actionable, and ready for design, manufacturing, or project planning.

We’ve helped teams reduce rework, avoid shutdown delays, and get projects right the first time.

Ready to See What It Looks Like?

Whether you’re a site supervisor, a plant engineer, or just looking for a smarter way to manage infrastructure, 3D scanning could be the tool that makes your job easier.

👉 Check out the full details here:

www.hamiltonbydesign.com.au/3d-laser-scanning

Or, if you’d prefer to talk through how it might work for your site, we’re just a call or email away.

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Why Engineers, Designers & Project Managers Are Turning to 3D Scanning and CAD Modelling

In engineering and fabrication, the margin for error is razor-thin. A few millimetres off can mean costly rework, delays, or worse — safety issues. At Hamilton By Design, we believe the future of precision engineering lies in combining smart data capture with expert design workflows. That’s why more businesses are moving away from guesswork and toward 3D laser scanning and CAD modelling as standard practice.

We’ve put together a detailed overview of our services and methods in a recent blog post that explains how we help industry clients across Australia deliver with confidence.

📌 Read the full post here:
👉 3D Scanning & CAD Modelling Services

🔍 What’s the Big Deal About 3D Scanning?

Traditional site measurements and hand-drawn markups are time-consuming, error-prone, and hard to communicate between disciplines. With 3D laser scanning, we can capture complex geometry quickly and accurately — from plant layouts and piping to structural steel and mobile machinery.

Using FARO laser scanning technology, we generate high-resolution point clouds that form the foundation for everything that follows — whether that’s clash detection, fabrication detailing, or a full digital twin.

It’s fast, accurate, and incredibly efficient — especially on live sites where access is limited and downtime is costly.

🧩 CAD Modelling That Fits — Literally and Logically

Once the scan is complete, our team of experienced mechanical designers converts that data into solid CAD models, tailored to your workflow.

Whether you need:

  • Accurate as-built documentation

  • Reverse-engineered mechanical components

  • Custom fabrication-ready drawings

  • Plant modification layouts

We deliver models that integrate seamlessly with your existing systems — whether you use SolidWorks, Inventor, Revit, or MicroStation.

Our CAD modelling isn’t just visual. It’s functional. It’s engineered for fit, fabrication, and future upgrades.

👷‍♂️ Real-World Applications Across Industry

Our clients range from mining operations and water utilities to fabrication shops and site-based engineering firms. In all cases, the common problem is the same: they need to understand what’s really there before they design what comes next.

Some recent use cases include:

  • Replacing worn mechanical components with no existing drawings

  • Planning plant upgrades where outdated PDFs weren’t reliable

  • Creating fabrication models from legacy assets

  • Capturing geometry for safety reviews and clearances

If your team still relies on measurements taken with a tape measure or outdated hand sketches, there’s a better way.

📌 Don’t Guess. Scan. Model. Deliver.

At Hamilton By Design, we’ve been providing CAD modelling since 2001, and offering 3D scanning since 2017. We’ve built our reputation on doing it right the first time — with engineering logic, practical experience, and technology that works.

If you want to understand how 3D laser scanning and CAD modelling can reduce risk and deliver better results, we invite you to read our full blog post:

👉 3D Scanning & CAD Modelling Services

Let’s take the guesswork out of your next project.

Mechanical Engineering | Structural Engineering

Mechanical Drafting | Structural Drafting

3D CAD Modelling | 3D Scanning

www.hamiltonbydesign.com.au

 

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Mechanical Engineering at the Heart of Mining on the Central Coast

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1. Setting the Scene: The Central Coast & Its Industrial Backbone

Home to nearly 350,000 people across Gosford, Wyong, Terrigal, and beyond, the Central Coast is well-known for its beaches and bushland—yet it also supports a robust industrial and mining‑services sector (Jora, Wikipedia). With growing infrastructure demands and proximity to resource projects like the Wallarah 2 coal proposal near Wyong (Wikipedia), mechanical engineers play a pivotal role behind the scenes.

2. What Do Mechanical Engineers Do in Mining on the Coast?

Mechanical engineers in mining and related heavy industries are responsible for:

  • Design & Maintenance: Planning, designing, and overseeing maintenance of critical mineral processing plants, machinery, conveyors, trucks and drilling rigs (Jobsora).

  • Automation Integration: Implementing robotics, programmable logic controllers (PLCs), remote operation systems, and predictive maintenance tools .

  • Health & Safety Compliance: Ensuring mechanical systems meet stringent safety regulations and operator protection standards (Jora).

  • Environmental Efficiency: Optimising equipment to reduce energy use, emissions, and noise—all while supporting mine rehabilitation efforts .

3. Job Opportunities in the Region

Recent job listings highlight robust opportunities for mechanical engineers across the Coast:

  • Mining Mechanical Engineer roles are regularly advertised in Gosford/Lisarow, appearing in SEEK and Jora job postings (SEEK).

  • Roles span senior design positions to hands‑on maintenance engineering—offering full-time opportunities with firms like Wabtec, Hyundai Rotem, Boral, and Coffey (SEEK).

  • Entry-level and graduate engineering roles are also available through pathways like Central Coast Council traineeships and TAFE NSW programs (Central Coast Council).

4. Industry Trends and What You’ll Need

As described by Titan Recruitment, the mining sector is embracing several transformative trends (Titan Recruitment):

  1. Automation & Robotics: Engineers are tasked with integrating autonomous machinery and control systems.

  2. Digital & Data Analytics: Skills in condition monitoring, sensors, and predictive analytics are in demand.

  3. Sustainability Focus: There’s emphasis on clean, efficient systems that reduce environmental footprint.

  4. Complex Machine Design: As equipment sophistication grows, so does the need for mechanical expertise.

  5. Asset Reliability & Safety: Mechanical engineers must ensure zero-fault operation in harsh mining environments.

  6. Site-to-System Integration: Engineers coordinate across disciplines—mechanical, electrical, structural—to optimise operations.

  7. Continuous Upskilling: Ongoing education—through TAFE NSW, professional certifications, and in-house training—is critical.

5. Training & Career Pathways on the Central Coast

🎓 Education & Apprenticeships

  • TAFE NSW (Hunter & Central Coast) offers mechanical and engineering trade training, forming a strong foundation for local roles (Wikipedia).

  • Central Coast Council provides apprenticeships and traineeships in mechanical fields—ideal stepping stones into industry .

🏢 Local Industry Experience

  • Firms like Wabtec, Hyundai Rotem, Boral, Coffey, and Wright Engineering in Somersby/Gosford offer vital on-the-job training and progression (SEEK).

  • Mining-support businesses across the Central Coast employ engineers to design, maintain, and improve heavy-duty plant and machinery.

6. Why the Central Coast Is a Great Base for Mining Engineers

  • Proximity to Projects: Infrastructure supporting coal drilling and mineral processing connects easily with local towns via major transport routes in and out of Gosford (Jobsora, Wikipedia).

  • Balanced Lifestyle: Work-life harmony blends regional industry jobs with coastal living and access to national parks (Indeed).

  • Clear Career Pathways: Education, apprenticeships, and employers form a supportive ecosystem—from bedrock training to senior site leadership.

Final Takeaway

Mechanical engineers are essential to mining operations on the Central Coast—ensuring machinery runs efficiently, safely, and sustainably. With strong local education pathways, active job markets, and growing tech trends, the region offers rewarding careers tied to both industrial innovation and community lifestyle.

Ready to design, maintain, and optimise the backbone of mining? The Central Coast has the foundation—and the opportunity—awaiting mechanical engineers eager to build the future.

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

Central Coast | Mount Isa | Brisbane | Cairns | Darwin

Published on Hamilton by Design — shaping engineering futures in NSW’s Central Coast

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