Engineering in Dubbo and 3D Scanning

3D Scanning in Dubbo

How Hamilton By Design Supports Regional NSW With 3D LiDAR Scanning, Engineering, 3D CAD Modelling & Drafting

Dubbo is one of regional NSW’s most important inland hubs — a crossroads for agriculture, transport, utilities, manufacturing, defence, construction, and regional infrastructure. Its strategic central location and industrial diversity make it a city that relies heavily on precision engineering, reliable documentation, and efficient project delivery.

As facilities expand, upgrade, or transition into modern digital workflows, Dubbo’s industries increasingly require accurate site data, engineering-grade modelling, and fabrication-ready drawings.
Hamilton By Design delivers exactly that.

We bring 3D LiDAR laser scanning, mechanical and structural engineering, 3D CAD modelling, and professional drafting directly to Dubbo’s industrial, agricultural and construction sectors — supporting clients who need certainty, accuracy, and efficient turnaround.

Why Dubbo Is Unique

What makes Dubbo stand out from other regional centres?

1. A major inland logistics & infrastructure hub
Dubbo sits at the intersection of key freight, rail and road corridors, supporting agriculture, mining supply lines, warehousing, utilities, and transport infrastructure.

2. Strong manufacturing and fabrication capability
Local workshops, steel fabricators, machinery builders, and transport-equipment manufacturers rely on accurate measurements and engineering documentation to minimise rework and site downtime.

3. Agriculture, water infrastructure & processing facilities
Irrigation systems, water treatment assets, processing facilities and agricultural mechanical plants demand precise alignment, structural integrity, and reliable as-built data.

4. Growing capital works & regional development
Government, utilities, councils, commercial builders and engineering firms increasingly require digital workflows — 3D models, scans, clash detection and accurate documentation.

This combination makes Dubbo an ideal match for engineering-led scanning and digital-first design.

3D LiDAR Laser Scanning in Dubbo

Accurate data is the foundation of every successful engineering project.
Hamilton By Design provides high-accuracy 3D LiDAR scanning that captures real-world geometry to millimetre-level precision — ideal for:

industrial plants & mechanical systems
agricultural processing equipment
structural steel, frames, conveyors & platforms
utilities, pumping stations & pipework
warehouses, sheds & fabrication workshops
site upgrades, retrofits and brownfield expansions

Our scans eliminate guesswork, reduce site time, and prevent costly fabrication errors.

Learn more about our scanning capabilities:
3D Laser Scanning

Turning Scans Into Intelligent Models — 3D CAD Modelling

Once Dubbo sites are scanned, Hamilton By Design converts point-cloud data into accurate 3D CAD models for engineering, fabrication and construction.

We provide:

detailed mechanical assemblies
structural steel modelling
equipment and plant layouts
GA drawings, isometrics and BOMs
clash detection and fit-up verification
digital twins for future asset management

This ensures fabricators, installers and engineers all work from the same accurate source of truth.

Explore this service:
3D CAD Modelling

Engineering Services for Dubbo’s Industrial Needs

From agricultural machinery to pumping stations, civil structures, metal fabrication and industrial facilities, Dubbo relies on strong mechanical and structural engineering.

Hamilton By Design provides:

mechanical design and equipment layout
structural design of platforms, frames, supports
integrity assessments of existing structures
modification and upgrade design for brownfield assets
shutdown-driven engineering and fit-up solutions
workflow and plant-efficiency improvements

We also offer advanced simulation and verification tools.

Engineering validation & simulation:
FEA Capabilities

Whether you’re fabricating a new platform, installing conveyors, adjusting equipment clearances or updating plant layouts — we ensure every design decision is backed by engineering certainty.

Drafting & Fabrication-Ready Documentation

Good engineering is only as strong as the drawings that support it.
Hamilton By Design produces highly detailed, fabrication-ready drafting packages including:

GA drawings
detail drawings
weldment documentation
pipework & isometric drawings
assemblies & exploded views
bill of materials (BOM)
issue-for-construction (IFC) documentation
as-built updates from LiDAR scans

Our drawings are accurate, clean, and ready for immediate hand-off to fabricators and installers.

Drafting services:
Drafting

End-to-End Workflow for Dubbo Projects

With Hamilton By Design, clients benefit from a seamless engineering pipeline:

Scan — High-accuracy laser capture
Model — 3D CAD conversion and layout
Engineer — Structural & mechanical design
Validate — Simulation, FEA, fit-checks
Draft — Fabrication & construction documentation
Deliver — A complete, integrated package

One provider. One workflow. One accountable source.

Why Dubbo Chooses Hamilton By Design

Millimetre-accurate scanning reduces fabrication risk
Engineers who understand real-world brownfield constraints
Fast turnaround for shutdowns and critical upgrades
Experience across agriculture, water treatment, utilities, workshops & manufacturing
Clear communication, professional standards and end-to-end compliance

Dubbo’s industrial economy keeps NSW moving. Our job is to ensure your assets, upgrades and fabrication projects are delivered with precision.

Our Clients

6 December 202512 December 2025

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

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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.

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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

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#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

2 August 20252 August 2025

Maximising Uptime at Transfer Points: How Hamilton By Design Optimises Chutes, Hoppers, and Conveyors for the Mining Industry

In the mining industry, system uptime isn’t just a goal—it’s a necessity. Transfer points such as chutes, hoppers, and conveyors are often the most failure-prone components in processing plants, especially in high-wear environments like HPGR (High Pressure Grinding Rolls) circuits. Abrasive ores, heavy impact, fines accumulation, and moisture can all combine to reduce flow efficiency, damage components, and drive up maintenance costs.

At Hamilton By Design, we help mining clients minimise downtime and extend the life of their material handling systems by applying advanced 3D scanning, DEM simulation, smart material selection, and modular design strategies. This ensures that transfer points operate at peak efficiency—day in, day out.

Here’s how we do it:

Optimised Flow with DEM-Based Chute & Hopper Design

Flow blockages and misaligned velocities are among the biggest contributors to transfer point failure in the mining industry. That’s why we use Discrete Element Method (DEM) simulations to model bulk material flow through chutes, hoppers, and transfer transitions.

Through DEM, we can simulate how different ores—ranging from dry coarse rock to sticky fines—move, compact, and impact structures. This allows us to tailor chute geometry, outlet angles, and flow paths in advance, helping:

Prevent material buildup or arching inside hoppers and chutes
Align material velocity with the conveyor belt speed using hood & spoon or trumpet-shaped designs
Reduce wear by managing trajectory and impact points

Optimised flow equals fewer shutdowns, longer equipment life, and better plant throughput.

Wear-Resistant Liners & Material Engineering

Not all wear is the same—and neither are the materials we use to combat it. By studying the abrasion and impact zones in your chute and hopper systems, we strategically apply wear liners suited to each application.

Our engineering team selects from:

AR (Abrasion-Resistant) steels for high-wear areas
Ceramic liners in fines-rich or ultra-abrasive streams
Rubber liners to absorb shock and reduce noise

This approach reduces liner replacement frequency, improves operational safety, and lowers the risk of unplanned shutdowns at key transfer points.

3. Dust and Spillage Control: Cleaner, Safer Operation

Dust and spillage around conveyors and transfer chutes can lead to extensive cleanup time, increased maintenance, and health hazards. At Hamilton By Design, we treat this as a core design challenge.

We design chutes and hoppers with:

Tight flange seals at interface points
Enclosed transitions that contain dust at the source
Controlled discharge points to reduce turbulent material drops

This reduces environmental risk and contributes to more consistent plant performance—especially in confined or enclosed processing facilities in the mining industry.

4. Modular & Accessible Designs for Faster Maintenance

When liners or components need replacement, every minute counts. That’s why our chute and hopper systems are built with modular sections—each engineered for fast removal and reinstallation.

Key maintenance-driven design features include:

Bolt-on panels or slide-in liner segments
Accessible inspection doors for safe visual checks
Lightweight modular components for easy handling

These details reduce labour time, enhance safety, and keep your plant online longer—especially critical in HPGR zones where throughput is non-stop.

5. Precision 3D Scanning & 3D Modelling for Retrofit Accuracy

One of the most powerful tools we use is 3D scanning. In retrofit or brownfield projects, physical measurements can be inaccurate or outdated. We solve this by conducting detailed laser scans that generate accurate point cloud data—a precise digital twin of your plant environment.

That data is then transformed into clean 3D CAD models, which we use to:

Design retrofits that precisely match existing structure
Identify interferences or fit-up clashes before fabrication
Reduce install time by ensuring right-first-time fits

This scan-to-CAD workflow dramatically reduces rework and error margins during installation, saving time and cost during shutdown windows.

Real-World Application: HPGR & Minerals Transfer Systems

In HPGR-based circuits, transfer points between crushers, screens, and conveyors experience high rates of wear, dust generation, and blockages—particularly where moisture-rich fines are present.

Here’s how Hamilton By Design’s methodology addresses these pain points:

DEM-based flow modelling ensures the HPGR discharge flows cleanly into chutes and onto conveyors without buildup.
Hood/spoon geometries help track material to belt velocity—minimising belt wear and reducing misalignment.
Strategic liner selection extends life in critical wear zones under extreme abrasion.
Modular chute designs allow for fast liner swap-outs without major disassembly.
3D scanning & CAD design ensures new chute sections fit seamlessly into existing HPGR and conveyor frameworks.

By designing smarter transfer systems with these technologies, we enable operators to reduce downtime, increase liner life, and protect critical assets in high-throughput mining applications.

Uptime Benefits at a Glance

Performance Area	Impact on Mining Operations
Smooth bulk material flow	Fewer clogs, improved throughput, longer operating cycles
Velocity-matched discharge	Lower conveyor belt wear and downtime
Robust wear protection	Longer life, fewer liner replacements
Modular design	Faster maintenance turnarounds during scheduled shutdowns
3D scanning & CAD integration	Precise fit, reduced installation time, fewer errors during retrofit

Final Word: Engineering That Keeps the Mining Industry Moving

At Hamilton By Design, we combine mechanical engineering expertise with 3D modelling, material flow simulation, and smart fabrication practices to deliver high-performance chute, hopper, and transfer point systems tailored for the mining industry.

Whether you’re dealing with a problematic HPGR discharge, spillage issues, or planning a brownfield upgrade, our integrated design process delivers results that improve reliability, extend service life, and protect uptime where it matters most.

Looking to retrofit or upgrade transfer systems at your site?
Let’s talk. We bring together 3D scanning, DEM modelling, practical engineering, and proven reliability to deliver systems that work—from concept through to install.

Reach out at contact@hamiltonbydesign.com.au

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