Proven Engineering. Real Results.
Every project starts with a challenge — tight shutdowns, outdated drawings, structural fatigue, or a need to innovate fast.
At Hamilton By Design, we bring practical design engineering, LiDAR scanning, and SolidWorks expertise together to deliver reliable, measurable outcomes for clients across mining, manufacturing, and data-centre infrastructure.
Explore some of our featured case studies below.
CHPP Chute & Launder Replacement – Hunter Valley
Scope: Redesign and replacement of a primary discharge chute and launder system within a coal wash plant shutdown.
Challenge: The original chute geometry caused material hang-ups, high wear, and unplanned downtime.
Our Approach:
- 3D laser scan of as-built geometry to capture alignment constraints
- SolidWorks 3D modelling and flow verification
- FEA structural validation to AS 3990 and AS 4100
- Prefabrication validation and bolt-access checks
Outcome:
Reduced install time by 38 %, eliminated flow bottlenecks, and improved liner change-out safety.
3D LiDAR Scan-to-Model Retrofit – Central Coast
Scope: Full as-built capture of process plant and mechanical upgrade integration.
Challenge: No reliable drawings existed; site shutdown window limited to 24 hours.
Our Approach:
- High-accuracy terrestrial LiDAR scanning
- Point-cloud registration and SolidWorks conversion
- Clash detection and layout optimisation
- Deliverables in STEP and DWG formats
Outcome:
Delivered verified as-built model within 48 hours, enabling prefabrication of pipe spools with zero site rework.
Structural Frame Validation – Manufacturing Facility
Scope: Lifting and access frame redesign for production line maintenance.
Challenge: Existing frame lacked design documentation and had unknown load paths.
Our Approach:
- Reverse-engineered frame geometry using scanning
- Conducted FEA load analysis to AS 4991 (Lifting Devices)
- Updated design and certification drawings
Outcome:
Achieved compliance, extended equipment life, and avoided costly frame replacement.
Modular Data-Centre Rack Design – Sydney
Scope: Design and verification of modular rack and cooling infrastructure.
Challenge: High-density data-centre upgrade required prefabricated mechanical assemblies with tight tolerances.
Our Approach:
- Parametric SolidWorks models with integrated cable-tray routing
- CFD and FEA integration for airflow and load validation
- Fabrication drawings optimised for CNC manufacture
Outcome:
Cut installation time by 60 %, achieving on-site plug-and-play assembly.
Pump Box & Pipe Spool Replacement – Bowen Basin
Scope: Replace corroded steel pump boxes and spools under constrained shutdown.
Challenge: Limited access and poor documentation of existing plant.
Our Approach:
- Laser scanning and model overlay with prefabrication QA
- SolidWorks modelling of new spools and supports
- On-site installation alignment checks
Outcome:
Zero interference fits and a fully verified installation delivered on schedule.