3D Laser Scanning & Mechanical Engineering Solutions
In today’s fast-paced engineering and construction industries, precision and efficiency are everything. Whether you’re managing a large-scale infrastructure project in Brisbane, creating a mechanical prototype in Perth, or needing accurate as-built data for a site in the Hunter Valley, 3D laser scanning and expert mechanical design services are game changers.
At Hamilton Design, we specialise in connecting cutting-edge scanning technology with skilled mechanical designers and structural drafting services to deliver seamless, accurate solutions for every stage of your project.
The Power of 3D Laser Scanning
3D laser scanning is transforming the way engineers, architects, and manufacturers work. By capturing millions of data points with millimetre accuracy, laser scanning creates a highly detailed 3D representation of your asset, site, or structure.
Our team provides 3D laser scanning services in Perth, Brisbane, and Melbourne, as well as laser scanning in the Hunter Valley, helping clients save time and avoid costly rework. This technology is ideal for:
Capturing as-built conditions before design or construction.
Supporting plant upgrades and facility expansions.
Documenting heritage structures and complex geometries.
Reducing site visits with accurate digital models.
Reverse Engineering & Mechanical Design
In addition to scanning, we offer reverse engineering services in Perth and beyond. By combining point cloud data with CAD modelling, we can recreate components, optimise designs, and prepare manufacturing-ready files.
Our mechanical engineers and mechanical designers bring years of experience in 3D mechanical engineering, design and manufacturing mechanical engineering, and problem-solving for a wide range of industries. From bespoke machinery to process equipment, we deliver solutions that work.
Structural Drafting & Project Support
No project is complete without clear, accurate documentation. Our skilled drafters in Hamilton and across Australia provide high-quality structural drafting services that integrate seamlessly with your workflows.
Whether you need shop drawings, fabrication details, or BIM-ready models, our team ensures every line and dimension is correct — saving you time and cost on-site.
Why Choose Hamilton Design?
Nationwide Reach: Serving clients with 3D scanning services in Perth, Brisbane, and Melbourne, and supporting projects in the Hunter Valley.
Complete Solutions: From scanning to modelling to mechanical engineering design.
Accuracy & Efficiency: Reduce project risk and improve decision-making with reliable data.
Experienced Team: Skilled mechanical engineers and drafters who understand your industry.
Ready to Get Started?
If you’re looking for mechanical engineering companies that deliver precision, innovation, and reliability, Hamilton Design is ready to help. Whether you need laser scanning in Perth or Brisbane, structural drafting, or full mechanical design services, our team can support your next project from concept to completion.
📞 Contact us today to discuss your project requirements and find out how our 3D laser scanning and mechanical engineering design solutions can save you time and money.
Collaboration is increasingly centred around 3D data. Modern platforms now let teams review, comment on, and markup native 3D models directly inside the design environment. Instead of relying solely on screenshots or static drawings, stakeholders can spin, section, and measure live models for better context. Real-time update notifications and cloud-connected revision control ensure that scanned 3D data and parametric CAD models stay synchronized — critical when working with reality capture data that represents the as-built environment. Hybrid data management options combine local PDM systems with cloud platforms, supporting distributed teams handling massive point clouds or mesh data. This tight integration means that model changes — whether from new design iterations or updated scans — propagate instantly across the project team. Decision-making becomes more visual and informed, keeping everyone aligned around a single, authoritative 3D dataset. Collaboration is no longer a separate process but embedded into daily 3D workflows.
2. Smarter Part Modelling
3D modelling tools are now more intelligent and better suited for working with scan-derived geometry. Designers can quickly apply chamfers, fillets, and shells across complex surfaces, even those imported from meshes or point cloud extractions. Automated bend notch creation and sheet metal tools are optimized to work with geometry derived from scanning existing parts, making reverse-engineering and fabrication preparation much faster. Reference geometry patterning allows engineers to build parametric frameworks over point cloud regions, speeding up master model creation. Cleanup utilities now support selectively removing unnecessary features or smoothing noisy scan data without rebuilding the entire model history. These advances turn what used to be a labour-intensive process into a streamlined workflow that transforms raw reality capture data into production-ready models. The focus is on reducing friction between physical and digital — allowing engineers to move quickly from scan to design, then to manufacturing.
3. Large Assembly Performance
Point cloud and mesh datasets are often extremely large, so performance improvements are critical. Modern CAD platforms now handle assemblies containing both traditional parametric models and massive scan data without bringing systems to a crawl. Engineers can duplicate components while maintaining mates, overlay scans onto assemblies to check fit, and perform interference detection even in lightweight modes. Visualization performance has been tuned for high-density point clouds, allowing smooth pan, zoom, and rotate interactions even with billions of points. Simplification and decimation tools let users strip out unneeded scan detail for faster load times while retaining critical geometry. Seamless transitions between lightweight review and full edit mode make it possible to work interactively with scanned environments. This capability is especially valuable for plant layout, construction validation, and retrofitting projects, where the ability to handle large, mixed-format 3D datasets directly within assemblies is a competitive advantage.
4. Enhanced Drawings and Documentation
Although 3D is the primary medium, 2D documentation remains essential — especially for suppliers and manufacturing partners. Modern CAD environments generate drawings directly from parametric models or scan-based reconstructions, ensuring that documentation matches the latest as-built conditions. Multi-approval stamps, BOM quantity overrides, and standards compliance tools make it easy to document parts created from reverse engineering or field measurement data. Automatic view generation and model-based definition (MBD) help reduce the reliance on fully manual drawings, embedding dimensions and tolerances directly into the 3D model where possible. For projects using scans, section views can be cut through the point cloud or mesh to produce accurate reference drawings without redrawing geometry. These improvements ensure that documentation is both faster to produce and more accurate — giving fabrication teams confidence that the deliverables reflect real-world conditions rather than idealized design intent.
5. Seamless ECAD/MCAD Integration
The convergence of 3D scanning and electronics integration is enabling more precise mechatronic design. Point cloud models of housings, enclosures, and factory floors can be combined with PCB outlines and component data for fit validation. Modern tools allow importing copper traces, vias, and keep-out regions into the mechanical model to run thermal or clearance checks directly against scanned geometry. This prevents collisions and ensures proper heat management early in the design cycle. Real-time synchronization between ECAD and MCAD domains means that if a scanned housing reveals unexpected tolerances, electrical designers can adjust their board layout accordingly. The result is a more accurate digital twin that accounts for both the designed and as-built states. This tighter integration avoids costly late-stage changes, shortens time-to-market, and ensures that mechanical and electrical systems are developed with a shared, reliable 3D reference that reflects physical reality.
6. Performance and Visualization
Visualization is where 3D scanning truly shines. GPU-accelerated engines now render massive point clouds, meshes, and parametric geometry in real time, allowing teams to virtually “walk through” captured environments or inspect reverse-engineered parts at full fidelity. Silhouette-based defeature tools can strip away irrelevant details while maintaining enough geometry for accurate reviews and clash detection. Cached mass property calculations extend to mesh and hybrid models, giving accurate weight and center of gravity data even from scan-derived parts. Photorealistic rendering using real-time ray tracing allows stakeholders to experience designs exactly as they will look, bridging the gap between scanned reality and proposed modifications. This level of visual fidelity improves collaboration, reduces the need for physical mock-ups, and accelerates stakeholder buy-in. High-quality 3D visualization is no longer a luxury — it is a daily tool for engineers, designers, and decision-makers alike.
7. Future Outlook
The future of 3D modelling is increasingly driven by AI and reality capture. Expect CAD platforms to automatically recognize features within point clouds — holes, slots, threads — and generate parametric features with minimal user input. Cloud-native workflows will make it easier to process extremely large scan datasets without local performance bottlenecks. Automated drawing generation and model-based definition will continue to reduce documentation overhead, while digital twin technology will tie live sensor data to scanned geometry for ongoing validation. Generative design powered by AI will be able to work directly with scanned environments, proposing optimized solutions that account for real-world constraints. This convergence of scanning, modelling, and simulation promises a future where physical and digital coexist seamlessly — enabling engineers to capture, design, simulate, and validate with unprecedented speed and accuracy, ultimately transforming how products, factories, and infrastructure are created and maintained.
In today’s world, accuracy and efficiency can make or break a project. Whether you’re working in architecture, construction, engineering, or product design, you need reliable data — and you need it fast. That’s where 3D point clouds come in.
But there’s an important catch: not all scans are created equal. The difference between an average scan and a great one often comes down to the person behind the scanner. Having someone who understands 3D modeling take the scans can dramatically improve your project’s accuracy, reliability, and overall success.
Let’s break down why.
The Power of 3D Point Clouds
Point clouds are essentially millions of tiny data points that capture the shape of an object, room, or entire site. Together, they create a highly detailed digital snapshot of the real world.
Here’s why this matters:
Precision you can trust – Point clouds deliver incredibly detailed measurements, capturing even the smallest curves and angles.
Nothing gets missed – Multiple scan angles ensure a full, 360° view of your site or object.
Speed and efficiency – What used to take hours (or days) with manual measurements can be captured in minutes.
Built-in context – You’re not just getting numbers; you’re getting a complete digital environment to work inside.
Future-proof data – Once you have a scan, you have a permanent record of your space, ready to use months or years later.
From clash detection to as-built verification, point clouds save time, reduce errors, and make collaboration across teams smoother than ever.
Why the Person Taking the Scan Matters
While technology is powerful, experience is what makes the results reliable. Having a skilled 3D modeler operate the scanner can be the difference between a good project and a great one.
Here’s why an expert makes all the difference:
They know what matters – A modeler understands which details are critical for your project and ensures they’re captured.
Fewer gaps, fewer surprises – Experienced pros know how to plan scan positions to cover every angle and avoid blind spots.
Cleaner, more accurate data – They reduce common issues like noise, misalignment, or missing sections that can throw off your model.
Time saved, headaches avoided – No one wants to redo a scan halfway through a project. A professional ensures you get it right the first time.
Confidence from start to finish – When you know your model is accurate, you can move forward with design and construction decisions without second-guessing.
In short: a great scanner operator doesn’t just deliver data — they deliver peace of mind.
The Bottom Line
3D point clouds are already transforming how projects are planned and delivered. But pairing them with an experienced 3D modeler takes things to the next level.
You’ll get better data, faster turnarounds, and a far lower risk of costly mistakes. And when your goal is to deliver projects on time, on budget, and with zero surprises, that’s an edge you can’t afford to miss.
Getting Coal, Hard Rock, and ROM Material Flow Right
Chute design is one of the most critical yet challenging aspects of mining and mineral processing. Whether you are handling coal, hard rock ore, or raw ROM material, chutes and transfer stations are the unsung workhorses of every operation. When designed well, they guide material smoothly, minimise wear, and keep conveyors running. When designed poorly, they cause blockages, spillage, excessive dust, and expensive downtime.
Modern chute design has moved far beyond rules of thumb and back-of-the-envelope sketches. Today, successful projects rely on accurate as-built data, particle trajectory analysis, and advanced Discrete Element Method (DEM) simulation to predict, visualise, and optimise material flow before steel is cut. In this article, we explore why these tools have become essential, how they work together, and where software can — and cannot — replace engineering judgement.
The Challenge of Chute Design
Coal and hard rock have very different flow behaviours. Coal tends to be softer, generate more dust, and be prone to degradation, while hard rock is more abrasive and can damage chutes if impact angles are not controlled. ROM material adds another level of complexity — oversize lumps, fines, and moisture variation can cause hang-ups or uneven flow.
Chute design must balance several competing objectives:
Control the trajectory of incoming material to reduce impact and wear
Prevent blockages by maintaining flowability, even with wet or sticky ore
Manage dust and noise to meet environmental and workplace health requirements
Fit within existing plant space with minimal modification to conveyors and structures
Be maintainable — liners must be accessible and replaceable without excessive downtime
Meeting all these goals without accurate data and simulation is like trying to design in the dark.
Capturing the Truth with 3D Scanning
The first step in any successful chute project is to understand the as-built environment. In many operations, drawings are outdated, modifications have been made over the years, and the real plant geometry may differ from what is on paper. Manual measurement is slow, risky, and often incomplete.
This is where 3D laser scanning changes the game. Using tripod-mounted or mobile LiDAR scanners, engineers can capture the entire transfer station, conveyors, surrounding steelwork, and services in a matter of hours. The result is a dense point cloud with millimetre accuracy that reflects the true state of the plant.
From here, the point cloud is cleaned and converted into a 3D model. This ensures the new chute design will not clash with existing structures, and that all clearances are known. It also allows maintenance teams to plan safe access for liner change-outs and other work, as the scanned model can be navigated virtually to check reach and access envelopes.
Understanding Particle Trajectory
Once the physical environment is known, the next challenge is to understand the particle trajectory — the path that material takes as it leaves the head pulley or previous transfer point.
Trajectory depends on belt speed, material characteristics, and discharge angle. For coal, fine particles may spread wider than the coarse fraction, while for ROM ore, large lumps may follow a ballistic path that needs to be controlled to prevent impact damage.
Accurately modelling trajectory ensures that the material enters the chute in the right location and direction. This minimises impact forces, reducing wear on liners and avoiding the “splash” that creates spillage and dust. It also prevents the material from hitting obstructions or dead zones that could lead to build-up and blockages.
Modern software can plot the trajectory curve for different loading conditions, providing a starting point for chute geometry. This is a critical step — if the trajectory is wrong, the chute design will be fighting against the natural path of the material.
The Power of DEM Simulation
While trajectory gives a first approximation, real-world flow is far more complex. This is where Discrete Element Method (DEM) simulation comes into play. DEM models represent bulk material as thousands (or millions) of individual particles, each following the laws of motion and interacting with one another.
When a DEM simulation is run on a chute design:
You can visualise material flow in 3D, watching how particles accelerate, collide, and settle
Impact zones become clear, showing where liners will wear fastest
Areas of turbulence, dust generation, or segregation are identified
Build-up points and potential blockages are predicted
This allows engineers to experiment with chute geometry before fabrication. Angles can be changed, ledges removed, and flow-aiding features like hood and spoon profiles or rock-boxes optimised to achieve smooth, controlled flow.
For coal, DEM can help ensure material lands gently on the receiving belt, reducing degradation and dust. For hard rock, it can ensure that the energy of impact is directed onto replaceable wear liners rather than structural plate. For ROM ore, it can help prevent oversize lumps from wedging in critical locations.
🖥 Strengths and Limitations of Software
Modern DEM packages are powerful, but they are not magic. Software such as EDEM, Rocky DEM, or Altair’s tools can simulate a wide range of materials and geometries, but they rely on good input data and skilled interpretation.
Key strengths include:
Ability to model complex, 3D geometries and particle interactions
High visualisation power for communicating designs to stakeholders
Capability to run multiple scenarios (different feed rates, moisture contents, ore types) quickly
However, there are limitations:
Material calibration is critical. If the particle shape, friction, and cohesion parameters are wrong, the results will not match reality.
Computational cost can be high — detailed simulations of large chutes with millions of particles may take hours or days to run.
Engineering judgement is still needed. Software will not tell you the “best” design — it will only show how a proposed design behaves under given conditions.
That’s why DEM is best used as part of a holistic workflow that includes field data, trajectory analysis, and experienced design review.
From Model to Real-World Results
When the simulation results are validated and optimised, the design can be finalised. The point cloud model ensures the chute will fit in the available space, and the DEM results give confidence that it will perform as intended.
This means fabrication can proceed with fewer changes and less risk. During shutdown, installation goes smoothly, because clashes have already been resolved in the digital model. Once commissioned, the chute delivers predictable flow, less spillage, and longer liner life.
Why It Matters More Than Ever
Today’s mining operations face tighter production schedules, stricter environmental compliance, and increasing cost pressures. Downtime is expensive, and the margin for error is shrinking.
By combining 3D scanning, trajectory modelling, and DEM simulation, operations can move from reactive problem-solving to proactive improvement. Instead of waiting for blockages or failures, they can design out the problems before they occur, saving both time and money.
Partnering for Success
At Hamilton by Design, we specialise in turning raw site data into actionable insights. Our team uses advanced 3D scanning to capture your transfer stations with precision, builds accurate point clouds and CAD models, and runs calibrated DEM simulations to ensure your new chute design performs from day one.
Whether you’re working with coal, hard rock, or ROM ore, we help you deliver designs that fit first time, reduce maintenance headaches, and keep production running.
Contact us today to see how our integrated scanning and simulation workflow can make your next chute project safer, faster, and more reliable.
When it comes to precision engineering, structural drafting, and mechanical design services, Hamilton by Design leads the way. We provide advanced 3D laser scanning solutions across Perth, Sydney, Brisbane, Melbourne, and the Hunter Valley — giving clients accurate data for smarter decisions and efficient project delivery.
3D Laser Scanning Across Australia
Our 3D laser scanning services capture exact measurements of your site, plant, or equipment to create detailed 3D point clouds and as-built documentation. This reduces rework, saves time, and improves project planning.
We offer:
3D Laser Scanning Perth & Fremantle – Industrial plant surveys, mining site scanning, and reverse engineering.
3D Laser Scanning Sydney & Melbourne – Building surveys, renovation planning, and structural inspections.
3D Laser Scanning Brisbane & Hunter Valley – Factory layouts, conveyor drive design, and structural scanning.
3D Laser Scanning for Engineering & Mining – Point cloud scanning, clash detection, and 3D modelling.
Our team uses the latest 3D scanning and LiDAR technology to produce millimetre-accurate results that engineers, architects, and builders can trust.
Structural Drafting & Design Services
Hamilton by Design provides structural drafting services across Australia, including:
Structural Design and Drafting – For residential, commercial, and industrial projects.
Steel Detailing & Shop Drawings – Produced to Australian drafting standards.
Structural Scanning Services Brisbane & Sydney – Helping engineers assess existing structures for upgrades or repairs.
Our experienced structural design engineers work closely with builders, architects, and civil engineers in Hamilton and beyond to deliver reliable, build-ready plans.
In today’s competitive manufacturing and fabrication landscape, the difference between success and frustration often comes down to one thing: how well you capture and use data. Traditional methods of measurement, drafting, and design simply can’t keep up with the complexity and pace of modern projects.
Enter point cloud scanning and 3D modeling — a transformative approach that is reshaping how manufacturers, fabricators, and engineers work together. But as powerful as this technology is, getting the most from it takes more than just buying a scanner. It takes expertise, insight, and a partner who can integrate this digital transformation seamlessly into your workflows.
So, is it time to level up and engage mechanical engineering consultants who can make this happen?
We think so — and here’s why.
From Point Cloud to 3D Model: A Game-Changer
When you scan a physical space, component, or assembly using modern laser scanning or photogrammetry, you capture millions of data points — a digital twin of reality. Converting that data into a precise 3D model opens the door to benefits like:
Pinpoint Accuracy: Say goodbye to guesswork and human measurement errors.
Faster Iteration: Generate manufacturing and fabrication drawings quickly, test design variations digitally, and accelerate your project timelines.
Improved Collaboration: Give engineers, fabricators, and stakeholders a single source of truth that everyone can see and work from.
Risk Reduction: Spot interferences, clashes, and potential problems before they become costly rework in the shop or on-site.
Future-Proofing: Create a digital foundation for maintenance, upgrades, and retrofits years down the line.
This isn’t just better engineering — it’s smarter business.
The Missing Piece: Expertise
Technology alone doesn’t guarantee success. A high-resolution point cloud is just data — and without the right people turning that data into insight, it won’t deliver its full value.
That’s where mechanical engineering consultants come in. By partnering with experts who understand both the technology and the application, you gain:
Tailored Workflows: A consultant knows how to align the process with your unique needs, whether it’s structural steel, piping systems, or custom machinery.
Best-Practice Modeling: Avoid bloated, unusable models or drawings that don’t reflect fabrication realities.
Integrated Solutions: Consultants ensure your 3D models, fabrication drawings, and QA processes work seamlessly with your existing systems.
Strategic Insight: Move beyond simply “drawing what’s there” to rethinking processes, improving efficiency, and reducing total cost of ownership.
Why Now Is the Perfect Time
Market pressures are increasing. Labor costs are rising. Margins are under strain. Mistakes are expensive — but digital solutions are more accessible than ever.
Your competitors are already exploring Industry 4.0 technologies like point cloud scanning, 3D modeling, and digital twins. The companies that succeed are the ones that move early, learn fast, and embed these practices into their operations.
Bringing in mechanical engineering consultants allows you to leapfrog the painful trial-and-error phase and start reaping the benefits from day one.
Level Up Your Engineering Today
If you’re still relying on outdated measurement methods, 2D drawings, and siloed workflows, now is the time to level up. Scanning, modeling, and digital collaboration aren’t “nice-to-haves” anymore — they’re the foundation of modern manufacturing and fabrication.
Engage a trusted mechanical engineering consultant who can:
Capture your as-built environment accurately
Convert point clouds into actionable 3D models
Deliver fabrication-ready drawings
Help you reduce risk, save time, and improve quality
The future of engineering is here. Don’t just keep up — get ahead.
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