3D LiDAR Scanning Hunter Valley Power Stations

FARO 3D laser scanner set up on a tripod capturing an industrial plant for LiDAR scanning and digital modelling, with Hamilton By Design branding in the corner.

Unlocking Accuracy, Safety and Efficiency for Critical Infrastructure

The Hunter Valley is home to some of Australia’s most significant power generation assets. These power stations — many of which have operated for decades — supply energy to mining operations, manufacturing facilities, regional communities and industries throughout New South Wales. As these plants age and undergo continual maintenance, upgrades and redevelopment, the importance of accurate, reliable and safe measurement methods becomes increasingly critical.

Traditionally, engineers and maintenance teams have relied on manual measurements, outdated drawings or partial documentation to plan upgrades or execute shutdown work. But in complex, congested and ageing plant environments, this introduces risks, delays and expensive rework.

This is why 3D LiDAR scanning in Hunter Valley power stations has emerged as one of the most valuable tools for modern asset management, engineering and maintenance planning. LiDAR provides a millimetre-accurate digital snapshot of real-world conditions, enabling smarter, safer and more predictable project outcomes.

This article explores the benefits, applications, and pros and cons of 3D LiDAR scanning and explains why Hunter Valley power stations stand to gain significantly from adopting this technology.

Why Power Stations Need Accurate As-Built Data

Power stations are among the most complex industrial facilities in Australia. Over decades of operation, they experience:

Structural deformation
Settlement and movement
Corrosion and wear
Numerous undocumented modifications
Equipment realignments
Tight access restrictions
Ageing steelwork and infrastructure

In these environments, original construction drawings rarely match reality. As a result, engineers planning upgrades, shutdowns or replacements often face:

Inaccurate interface points
Misaligned structures
Unpredictable installation conditions
High rework costs
Safety delays
Poor shutdown timing

3D LiDAR scanning offers a precise, digital representation of the site, giving engineers the confidence they need to design upgrades accurately and eliminate guesswork.

The Benefits of 3D LiDAR Scanning for Hunter Valley Power Stations

1. Unmatched Measurement Accuracy for Complex Assets

A power station contains thousands of interconnected components:

Boilers
Turbines
Structural platforms
Pipe networks
Pressure vessels
Ducting systems
Conveyor bridges
Cooling towers
Electrical cabinets
Steel supports

Capturing these geometries manually is nearly impossible.

3D LiDAR scanning provides millimetre-level accuracy across enormous plant areas, allowing engineers to:

Create precise as-built models
Validate structural alignment
Check pipe routes and clearances
Identify interferences
Understand deformation over time
Design new works based on real geometry

This level of data is invaluable for maintaining safe and compliant power-generation operations.

2. Major Safety Improvements

Power stations present significant safety risks:

High-voltage environments
Confined spaces
Elevated platforms
Hot surfaces
Restricted access
Operational machinery

Manual measurement often requires workers to climb structures, enter hazardous zones or physically reach difficult areas.

3D LiDAR scanning dramatically reduces risk by:

Capturing data from safe distances
Eliminating the need for repeated access
Reducing time in hazardous zones
Minimising interaction with live equipment

For Hunter Valley power stations with strict safety requirements, this is a major benefit.

3. Reduced Shutdown Duration and Cost

Shutdowns are among the most expensive events for power-generation facilities. Every hour counts.

With 3D LiDAR scanning:

Engineers define accurate scopes before shutdown
Fabricators receive precise data and cut steel correctly
Digital fit checks identify issues early
Installation is faster and smoother
Delays due to bad measurements are eliminated

This leads to shorter outages, safer work and fewer unexpected problems.

4. Supports Engineering, Design and Structural Integrity Works

Power stations frequently require:

Boiler upgrades
Turbine area modifications
Ducting and flue replacements
Pipework rerouting
Cooling-system upgrades
Structural strengthening
Platform and walkway replacements
Electrical equipment relocations

All of these tasks depend on accurate geometry.

3D LiDAR scanning supports engineering teams by providing:

Reference geometry for load calculations
Verified connection points
True alignment data
Accurate slope and deflection measurements
High-resolution drawings and 3D models

This ensures engineering decisions are made using verified, real-world information.

5. Perfect for Brownfield and Congested Environments

Power stations are some of the most complex brownfield assets in the industrial landscape. They contain layers of modifications, years of retrofits and areas where access is extremely limited.

3D LiDAR scanning excels at capturing:

Tight clearances
Overlapping structures
Equipment clusters
Interconnected pipes
Hard-to-reach surfaces

This makes it ideal for planning:

New platforms
Replacement ducting
Pipe realignments
Structural upgrades
Asset lifecycle extensions

The result: fewer surprises during installation.

6. Better Collaboration Between Teams

Power stations typically involve:

Maintenance teams
OEMs
Engineering consultants
Fabricators
Shutdown managers
Safety personnel
Project delivery teams

3D LiDAR scanning enables everyone to work from the same digital truth.

Point clouds and 3D models allow:

Remote site understanding
Clear communication
Digital reviews instead of repeated site visits
Improved planning alignment

For Hunter Valley projects involving multiple contractors, this significantly boosts performance.

Pros and Cons of 3D LiDAR Scanning

Like any technology, LiDAR has strengths and limitations. Understanding both helps power station operators make informed decisions.

Pros

✔ Extremely high accuracy

Millimetre precision for large and complex areas.

Fast data capture

Reduces time spent in hazardous areas.

Clear visibility of congested spaces

Captures geometry that traditional methods miss.

Enhances engineering confidence

Designers base work on verified conditions.

Reduces installation rework

Fabrication matches the real site exactly.

Supports digital engineering workflows

Perfect input for CAD, BIM, simulation and modelling.

Safer measurement practices

Less climbing, reaching and confined-space entry.

Cons

Requires skilled interpretation

Point cloud data must be processed by trained technicians or engineers.

Large file sizes

High-resolution scans require strong computing resources.

Reflective or transparent surfaces can create challenges

Requires technique or matte marking in some areas.

Upfront cost may seem higher

But it eliminates far greater downstream costs in rework and shutdown delays.

Despite these considerations, LiDAR scanning remains the most cost-effective measurement tool for power station environments.

Why Hunter Valley Power Stations Benefit More Than Most

The Hunter Valley industrial landscape presents unique challenges:

Ageing energy infrastructure
Multiple retrofits and undocumented modifications
Extremely tight maintenance windows
Harsh environmental conditions
Congested structures with difficult access
High safety standards
Heavy reliance on local fabrication accuracy

3D LiDAR scanning Hunter Valley power stations provides the one thing these facilities need most: confidence.

Confidence in measurements.
Confidence in fabrication.
Confidence during shutdowns.
Confidence in engineering decisions.
Confidence in safety performance.

Few regions stand to gain more from LiDAR than the Hunter.

Hamilton By Design: Supporting Hunter Valley Power Stations with Advanced LiDAR Solutions

Hamilton By Design brings together:

Engineering expertise
On-site scanning capability
CAD modelling and drafting
Fabrication-ready documentation
Digital fit-checking and clash detection
Mechanical and structural design experience

We understand the complex realities of power-station environments, and we deliver precise, reliable and engineering-ready digital data for:

Boiler upgrades
Turbine hall modifications
Structural replacements
Pipe rerouting
Platform and access upgrades
Ducting and flue modifications
Cooling tower projects
Balance-of-plant improvements

Every model, point cloud and drawing is produced with installation success and fabrication accuracy in mind.

Conclusion: 3D LiDAR Scanning is the New Standard for Hunter Valley Power Stations

As the Hunter Valley transitions into a future of renewable generation, asset extension and industrial redevelopment, 3D LiDAR scanning stands out as a technology that delivers real, immediate value.

It improves safety.
It increases accuracy.
It reduces rework.
It enables better engineering.
It shortens shutdowns.
It lowers project risk.

Power stations across the Hunter Valley rely on critical, ageing and highly complex infrastructure — infrastructure that demands accurate, reliable digital measurement.

Hamilton By Design is proud to support the region with advanced laser scanning technologies that empower engineers, fabricators, supervisors and project managers to work smarter, safer and more efficiently.

3D Laser Scanning

Hunter Valley Laser Scanning: Transforming Engineering Accuracy Across Mining, Manufacturing and Infrastructure

3D Laser Scanning in Singleton and the Hunter: Delivering Accuracy for Mining, Manufacturing and Industrial Projects

Laser Scanning Hunter Valley: Delivering Engineering-Grade Accuracy for Mining, Manufacturing and Industrial Projects

Our clients

28 September 20257 December 2025

Seeing the Unseen: How LiDAR Scanning is Transforming Mining Process Plants

In modern mining, where uptime is money and safety is non-negotiable, understanding the geometry of your process plant is critical. Every conveyor, chute, pipe rack, and piece of equipment must fit together seamlessly and operate reliably — but plants are messy, dusty, and constantly changing. Manual measurement with a tape or total station is slow, risky, and often incomplete.

nfographic showing how LiDAR scanning is used in mining process plants, with illustrations of conveyors, crushers, tanks, mills and chutes. Labels highlight applications such as stockpile volumetrics, crusher inspections, safety and risk management, chute wear and blockages, mill wear measurement, tank deformation monitoring and creating digital twins.

This is where LiDAR scanning (Light Detection and Ranging) has become a game-changer. By capturing millions of precise 3D points per second, LiDAR gives engineers, maintenance planners, and operators an exact digital replica of the plant — without climbing scaffolds or shutting down equipment. In this post, we’ll explore how mining companies are using LiDAR scanning to solve real problems in processing plants, improve safety, and unlock operational efficiency.

What Is LiDAR Scanning?

LiDAR is a remote sensing technology that measures distance by firing pulses of laser light and recording the time it takes for them to return. Modern terrestrial and mobile LiDAR scanners can:

Capture hundreds of thousands to millions of points per second
Reach tens to hundreds of meters, depending on the instrument
Achieve millimeter-to-centimeter accuracy
Work in GPS-denied environments, such as inside mills, tunnels, or enclosed plants (using SLAM — Simultaneous Localization and Mapping)

The output is a point cloud — a dense 3D dataset representing surfaces, equipment, and structures with stunning accuracy. This point cloud can be used as-is for measurements or converted into CAD models and digital twins.

Why Process Plants Are Perfect for LiDAR

Unlike greenfield mine sites, processing plants are some of the most geometry-rich and access-constrained areas on site. They contain:

Complex networks of pipes, conveyors, tanks, and structural steel
Moving equipment such as crushers, mills, and feeders
Dusty, noisy, and hazardous environments with limited safe access

All these factors make traditional surveying difficult — and sometimes dangerous. LiDAR enables “no-touch” measurement from safe vantage points, even during operation. Multiple scans can be stitched together to create a complete model without shutting down the plant.

Applications of LiDAR in Process Plants

1. Wear Measurement and Maintenance Planning

LiDAR has revolutionized how mines measure and predict wear on critical process equipment:

SAG and Ball Mill Liners – Portable laser scanners can capture the exact wear profile of liners. Comparing scans over time reveals wear rates, helping maintenance teams schedule relines with confidence and avoid premature failures.
Crusher Chambers – Scanning inside primary and secondary crushers is now faster and safer than manual inspections. The resulting 3D model allows engineers to assess liner life and optimize chamber profiles.
Chutes and Hoppers – Internal scans show where material buildup occurs, enabling targeted cleaning and redesign to prevent blockages.

Result: Reduced downtime, safer inspections, and better forecasting of maintenance budgets.

2. Retrofit and Expansion Projects

When modifying a plant — installing a new pump, rerouting a pipe, or adding an entire circuit — having an accurate “as-built” model is crucial.

As-Built Capture – LiDAR provides an exact snapshot of the existing plant layout, eliminating guesswork.
Clash Detection – Designers can overlay new equipment models onto the point cloud to detect interferences before anything is fabricated.
Shutdown Optimization – With accurate geometry, crews know exactly what to cut, weld, and install — reducing surprise field modifications and shortening shutdown durations.

3. Inventory and Material Flow Monitoring

LiDAR is not just for geometry — it’s also a powerful tool for tracking material:

Stockpile Volumetrics – Mounted scanners on stackers or at fixed points can monitor ore, concentrate, and product stockpiles in real time.
Conveyor Load Measurement – Stationary LiDAR above belts calculates volumetric flow, giving a direct measure of throughput without contact.
Blending Control – Accurate inventory data improves blending plans, ensuring consistent plant feed quality.

4. Safety and Risk Management

Perhaps the most valuable application of LiDAR is keeping people out of harm’s way:

Hazardous Floor Areas – When flooring or gratings fail, robots or drones with LiDAR payloads can enter the area and collect data remotely.
Fall-of-Ground Risk – High walls, bin drawpoints, and ore passes can be scanned for unstable rock or buildup.
Escape Route Validation – Scans verify clearances for egress ladders, walkways, and platforms.

Every scan effectively becomes a permanent digital record — a baseline for monitoring ongoing structural integrity.

5. Digital Twins and Advanced Analytics

A plant-wide LiDAR scan is the foundation of a digital twin — a living, data-rich 3D model connected to operational data:

Combine scans with SCADA, IoT, and maintenance systems
Visualize live process variables in context (flow rates, temperatures, vibrations)
Run “what-if” simulations for debottlenecking or energy optimization

As AI and simulation tools mature, the combination of geometric fidelity and operational data opens new possibilities for predictive maintenance and autonomous plant operations.

Emerging Opportunities

Looking forward, there are several promising areas for LiDAR in mining process plants:

Autonomous Scan Missions – Using quadruped robots (like Spot) or SLAM-enabled drones to perform routine scanning in high-risk zones.
Real-Time Change Detection – Continuous scanning of critical assets with alerts when deformation exceeds thresholds.
AI-Driven Point Cloud Analysis – Automatic object recognition (valves, flanges, motors) to speed up model creation and condition reporting.
Integrated Planning Dashboards – Combining LiDAR scans, work orders, and shutdown schedules in a single interactive 3D environment.

Best Practices for Implementing LiDAR

To maximize the value of LiDAR scanning, consider:

Define the Objective – Are you measuring wear, planning a retrofit, or building a digital twin? This affects scanner choice and resolution.
Plan Scan Positions – Minimize occlusions and shadow zones by preplanning vantage points.
Use Proper Registration – Tie scans to a control network for consistent alignment between surveys.
Mind the Environment – Dust, fog, and vibration can degrade data; choose scanners with appropriate filters or protective housings.
Invest in Processing Tools – The raw point cloud is only the start — software for meshing, modeling, and analysis is where value is extracted.
Train Your Team – Build internal capability for scanning, processing, and interpreting the results to avoid vendor bottlenecks.

Infographic showing a 3D LiDAR scanner on a tripod surrounded by eight best-practice principles: start with clear objectives, plan your scanning campaign, prioritize safety, optimize data quality, ensure robust registration and georeferencing, establish repeatability, integrate with downstream systems, and train people with documented procedures

LiDAR scanning is no longer a niche technology — it is rapidly becoming a standard tool for mining process plants that want to operate safely, efficiently, and with fewer surprises. From mill liners to stockpiles, from shutdown planning to digital twins, LiDAR provides a clear, measurable view of assets that was impossible a decade ago.

For operations teams under pressure to deliver more with less, the case is compelling: better data leads to better decisions. And in a high-stakes environment like mineral processing, better decisions translate directly to improved uptime, reduced costs, and safer workplaces.

The next time you’re planning a shutdown, a retrofit, or even just trying to understand why a chute is plugging, consider pointing a LiDAR scanner at the problem. You may be surprised at how much more you can see — and how much time and money you can save.

3D Scanning | Mining Surface Ops | 3D Modelling

Mechanical Engineering | Structural Engineering

Mechanical Drafting | Structural Drafting

3D CAD Modelling | 3D Scanning

Chute Design

SolidWorks Contractors in Australia

Hamilton By Design – Blog

21 September 20256 December 2025

Why 3D Point Clouds + Expert Modelers Are a Game-Changer for Your Projects

Infographic illustrating the 3D project data workflow, showing LiDAR scanners and drones capturing millions of data points, a designer modelling on a computer, and project teams validating accurate 3D data, highlighting benefits such as speed, accuracy, cost savings and project success.

Level Up your 3D Scans

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.

3D Modelling | 3D Scanning | Point Cloud Scanning

20 September 20256 December 2025

Chute Design in the Mining Industry

Infographic showing Hamilton By Design’s engineering workflow, including millimetre-accurate LiDAR reality capture, material-flow simulation, optimised chute designs, and safer, more efficient production outcomes. Two workers in PPE highlight reliable design and longer liner life, with icons representing time, cost and quality benefits.

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.

Illustration showing common problems with poorly designed material-handling chutes. A chute discharges material onto a conveyor while issues are highlighted around it: unpredictable material flow, material spillage, maintenance challenges, high wear, blockages, and dust and noise. Warning icons for downtime and cost appear on the conveyor, and workers are shown dealing with the resulting hazards and maintenance tasks.

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.

Illustrated graphic showing a tripod-mounted 3D laser scanner capturing millimetre-accurate as-built data in an industrial plant with conveyors and walkways. Speech bubbles highlight issues such as “Outdated drawings don’t tell the full story” and “Modifications rarely get documented.” The scan data is shown being visualised on a laptop, with notes describing full coverage of conveyors, walkways, and services. Benefits listed along the bottom include faster data collection, fewer site revisits, safer shutdowns, accurate starting point for design simulation, and safer outcomes that ensure designs fit first time.

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.

Illustration of an optimised chute design showing material flow represented by green particles, with check marks and gear icons indicating improved efficiency and engineered performance.

🖥 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.

Mechanical Engineering | Structural Engineering

Mechanical Drafting | Structural Drafting

3D Laser Scanning | 3D CAD Modelling | 3D Scanning

Chute Design

SolidWorks Contractors in Australia

Hamilton By Design – Blog

Consulting Engineers

About Us – Hamilton By Design

Hamilton By Design | 3D Scanning | Sydney | Perth | Brisbane | Mount Isa | Lidar Scanning

Contact us

20 September 202524 September 2025

3D Scanning

How 3D Laser Scanning is Redefining Reality for Design, Construction & Heritage

Imagine standing before a centuries-old cathedral, where every carved arch, every stained-glass pane, every weathered stone holds centuries of stories. Capturing its true form and condition with tape measure and camera? Tedious and prone to errors. But with 3D laser scanning, you can digitally freeze every detail—down to the imperfections—turning reality into an exact, manipulable model.

In an age where precision, speed, and data-driven decisions are non-negotiable, 3D laser scanning is no longer “nice to have”—it’s essential. Let’s explore what it is, why it’s transformative, where it’s being used most powerfully, and how you can harness its potential.

What Is 3D Laser Scanning?

At its core, 3D laser scanning sometimes called terrestrial laser scanning, (TLS) is the emission of laser pulses toward surfaces, recording the time it takes for those pulses to bounce back. From that comes a dense “point cloud” — billions of precise data points mapping shape, texture, orientation, and distance.

These point clouds become high-fidelity models, maps, meshes, or BIM ready files. Whether you’re scanning building exteriors, interiors, or industrial components, the result is more than just imagery—it’s measurable, analyzable geometry.

How It Works — The Process

Preparation & Planning

Define what you need: the level of detail (LOD), resolution, range, and whether external conditions (light, weather) will interfere.
Data Capture

Position the scanner at multiple stations to cover all surfaces. Use targets or reference markers for alignment and capture with overlapping scans.
Processing & Registration

Merge scans to align them properly, clean noise, filter out irrelevant data (like people, moving objects), calibrate.
Post-processing & Deliverables

Convert point clouds into usable outputs—floorplans, sections, elevations, 3D meshes, BIM models, virtual walkthroughs. Run analyses (clash detection, deformation etc.).
Integration & Use

Use the data in design, restoration, facility management, or documentation. The quality of integration (into BIM, GIS, CAD) is key to unlocking value.

Key Benefits

Benefit	What It Means in Practice	Real-World Impact
Extreme Precision	Sub-millimetre to millimetre accuracy depending on the scanner and conditions.	Less rework. Better fit for retrofit, renovation, or mechanical systems in tight tolerances.
Speed + Efficiency	Collect large amounts of spatial data in far less time than traditional measurement.	Faster project turnaround. Reduced site time costs.
Non-Contact / Low Disruption	Good for fragile structures, hazardous or difficult-to-access places.	Preserves integrity of heritage buildings; safer for workers.
Comprehensive Documentation	Full visual & geometric context.	Informs future maintenance. Acts as an archival record.
Better Decision Making & Conflict Detection	Early clash detection; scenario simulation; what-if modelling.	Avoids costly mistakes; helps build consensus among stakeholders.
Enhanced Visualisation & Communication	Stakeholders can see exactly what exists vs. what’s being proposed.	Improves client buy-in, regulatory approvals, fundraising.

Applications: Where It Shines

Architecture & Renovation: As-built models, restoration of heritage sites.
Infrastructure & Civil Engineering: Bridges, tunnels, rail track alignments.
Industrial & Manufacturing: Machine part audits, reverse-engineering, plant layout.
Heritage & Preservation: Documenting fragile monuments, archaeological sites.
Facility Management: Digital twins, maintenance, asset tracking.
Environment & Surveying: Terrain mapping, forestry, flood risk mapping (especially when combined with aerial systems or mobile scanning).

Challenges & Best Practices

Nothing is perfect. To get the most out of 3D laser scanning, anticipate and mitigate:

Environmental factors: Light, dust, rain, reflective surfaces can introduce noise.
Data overload: Massive point clouds are large; need strong hardware & efficient workflows.
Alignment & registration errors: Overlaps, control points, and calibration are vital.
Skill & Planning: Good operators + good planning = much better outcomes.

Key best practices:

Use reference targets for precise registration.
Capture overlap of 30-50% between scan positions.
Break project into manageable segments.
Clean noise early.
Think ahead about deliverables and how clients will use the data (design, BIM, VR etc.).

Case Studies & Stories

Heritage in Danger: A cathedral in Europe threatened by pollution and structural decay was laser scanned. The point cloud revealed minute deformations, enabling an accurate restoration plan—saving costs and preserving history.
Infrastructure Efficiency: A civil engineering firm reduced design clashes by 80% on a complex highway project by integrating scans with their BIM workflow.
Industrial Switch-Over: Manufacturing plant layout was reconfigured using scan data; downtime reduced because the virtual model matched reality better than the old blueprints.

Software, Tools & Ecosystem

While scanners are vital, the software ecosystem is what unlocks value. Tools that turn raw data into actionable insights include:

Reality capture tools (processing point clouds).
BIM / CAD integration (e.g. Revit, AutoCAD).
Visualization tools (VR, AR, walkthrough).
Data sharing & collaboration platforms.
Cloud storage / processing if large point clouds.

SaaS/cloud-based workflows are increasingly important to share among remote teams, facilitate stakeholder review, and ensure data is accessible beyond just technical users.

Why It Matters Now

Global pressures (heritage, sustainability, faster build cycles, remote work) are raising the bar.
Clients expect transparency, accuracy, minimized risk.
Regulatory compliance and “as-built” requirements are stricter.
Digital twins & smart infrastructure demand high fidelity data.

3D laser scanning acts as a bridge: between physical world and digital twin; between heritage past and future; between design promise and build reality.

If you have a survey scan and want to make sense of point cloud data, contact Hamilton By Design

Hamilton By Design

Mechanical Designers

Mechanical Engineers Design

3D Mechanical Engineering

Mechanical Engineering Consultants

3D Laser Scanning

#Scanning Sydney #3D Laser Scanning #3D Point Cloud Scanning #3D Laser Scanning Brisbane #3D Laser Scanning Mitcham London #3D Laser Scanning Perth #3D Laser Scanning Sydney #3D Mechanical Engineering

15 September 20259 December 2025

Hamilton by Design: Your Experts in 3D Laser Scanning & Mechanical Design

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.

Hamilton by Design services diagram showing four key areas: 3D Laser Scanning, Mechanical Design and Engineering, Structural Drafting and Design, and Industries Served. The chart lists services such as 3D point cloud scanning, as-built documentation, reverse engineering, mechanical product development, conveyor drive systems for mining, factory design consulting, FEA, structural steel detailing, and design for construction, manufacturing and industrial sectors. Industries served include construction and infrastructure, and residential and renovations. A footer reads ‘3D Laser Scanning and Mechanical Design Australia

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.

Infographic showing 3D laser scanning capturing industrial equipment to identify challenges such as vibration, movement, and fluid leaks, feeding into a 3D model that improves planning, reduces rework, and supports safer maintenance

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.

See Structural Engineering for more info

Mechanical Design & Engineering Solutions

We are a full-service mechanical design consultancy offering:

Mechanical Product Design & Development
Factory & Plant Layout Design
Conveyor Belt Drive Systems & Mining Equipment Design
Finite Element Analysis (FEA) and performance validation
Reverse Engineering Services Perth for spare parts and retrofits

Our team of mechanical engineers, drafters, and CAD designers ensures every project is efficient, safe, and cost-effective.

see Mechanical Engineering for more info

Industries We Serve

Hamilton by Design supports clients across:

Mining & Resources – Coal conveyors, feed thickeners, and vibrating equipment in Kalgoorlie and Mount Isa.
Construction & Infrastructure – As-built scanning and 3D modelling for building projects.
Manufacturing – Factory optimization and equipment design.
Residential Projects – Drafting services for home renovations and new builds in Hamilton and surrounding areas.

Why Partner with Hamilton by Design?

Choosing Hamilton by Design means working with mechanical design experts and structural drafters who are committed to accuracy, speed, and innovation.

Australia-Wide Coverage – Perth, Sydney, Melbourne, Brisbane, Hunter Valley
Cutting-Edge Technology – Laser scanning, CAD modelling, and 3D visualization
Expert Team – Experienced mechanical engineers and design consultants
Cost-Effective Solutions – Saving time, reducing errors, and minimizing rework

Get Started Today

Ready to transform your next project with 3D laser scanning, structural drafting, or mechanical design services?

Contact Hamilton by Design for a consultation and see how our team can deliver precise, efficient, and innovative solutions for your business.

Hamilton By Design – Blog

Consulting Engineers

About Us – Hamilton By Design

M	T	W	T	F	S	S
1	2	3	4	5	6	7
8	9	10	11	12	13	14
15	16	17	18	19	20	21
22	23	24	25	26	27	28
29	30	31