3D Scanning Engineering in Whyalla

3D Scanning in Whyalla

Whyalla is one of South Australia’s most engineering-driven regional cities. Built around steelmaking, port infrastructure, and heavy industry, it is a place where engineering is practical, site-focused, and shaped by decades of brownfield assets, modifications, and operational realities.

For engineers working in Whyalla, accuracy matters. Many assets have been upgraded, repaired, or adapted multiple times over their life, often with incomplete or outdated drawings. This is where engineering-led 3D LiDAR scanning and digital modelling become essential tools — not just nice-to-have technology.

Hamilton By Design supports Whyalla’s industrial, mining, port, and infrastructure sectors with 3D laser scanning, mechanical engineering, 3D modelling, FEA, and drafting, delivering data and designs that work in the real world.

Engineering Challenges Unique to Whyalla

Engineering in Whyalla is rarely greenfield. Most projects involve:

Existing steel structures and mechanical plant
Live operating environments
Marine corrosion and harsh conditions
Tight shutdown windows
Limited tolerance for rework

Successful projects depend on accurate as-built information, practical engineering judgement, and designs that can be fabricated and installed locally.

Hamilton By Design brings these elements together in a single workflow.

3D Laser Scanning for Whyalla Projects

High-accuracy 3D LiDAR laser scanning forms the foundation of our work in Whyalla.

Using engineering-grade scanners, we capture true as-built conditions of:

Steelworks and heavy industrial plant
Conveyors, chutes, and mechanical equipment
Port structures, wharves, and ship-loader interfaces
Buildings, platforms, and access structures

Unlike traditional surveys, 3D scanning records real geometry, including misalignment, deflection, corrosion loss, and historic modifications.

This data is used to:

Eliminate site rework
Reduce shutdown risk
Validate fit-ups before fabrication
Support safe and efficient upgrades

Learn more about our approach to
3D Laser Scanning

3D Modelling Built from Real As-Built Data

Once scanning is complete, the point cloud becomes the basis for accurate 3D CAD models.

Hamilton By Design produces SolidWorks-based models that reflect what is actually on site — not what old drawings suggest should be there.

Our 3D modelling services support:

Brownfield mechanical upgrades
Structural modifications
Clash detection and spatial checks
Fabrication-ready designs
Asset documentation and digital twins

For Whyalla projects, this approach significantly reduces risk, especially where legacy assets and tight clearances are involved.

Explore our modelling capability here:
3D CAD Modelling

FEA for Heavy Industry and Steel Assets

Whyalla engineering often involves ageing assets that must continue operating safely under modern standards. This is where Finite Element Analysis (FEA) plays a critical role.

Hamilton By Design uses FEA to assess:

Structural capacity of existing steelwork
Fatigue and stress concentrations
Load changes from modifications or upgrades
Deflection, buckling, and thermal effects

FEA allows informed decisions about:

Strengthening versus replacement
Extending asset life
Verifying compliance with current requirements

All analysis is grounded in real as-built geometry, improving confidence in results and recommendations.

Learn more about our analysis services:
FEA Capabilities

Engineering Drafting That Supports Construction

Clear, accurate documentation is critical for fabrication and installation in Whyalla’s industrial environment.

Hamilton By Design delivers engineering-ready drafting, including:

General arrangement drawings
Fabrication and workshop drawings
Installation and modification layouts
As-built documentation

Drafting is produced directly from scanned data and validated 3D models, ensuring drawings align with site reality.

View our drafting services here:
Drafting Services

Why Hamilton By Design in Whyalla?

What sets Hamilton By Design apart is engineer-led scanning and modelling. We don’t treat scanning as a standalone survey — it is integrated directly into engineering, analysis, and drafting workflows.

For Whyalla clients, this means:

Fewer assumptions
Less rework
Better shutdown outcomes
Designs that fit and function first time

From steelworks and port infrastructure to industrial plant and buildings, Hamilton By Design supports Whyalla projects with practical, accurate, and construction-focused digital engineering.

If you’re planning an upgrade, modification, or assessment in Whyalla, we’re ready to help — starting with the right data and carrying it through to fabrication-ready outcomes.

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11 December 202512 December 2025

3D Scanning Engineering in Geraldton

Delivering Accuracy, Efficiency & Engineering Certainty for WA’s Mid-West Industries

Geraldton is one of Western Australia’s most strategically important regional centres — a city where port operations, grain and mineral export infrastructure, heavy-industry fabrication, fishing, renewables, and large-scale construction all intersect. With its combination of coastal exposure, industrial logistics and expanding regional infrastructure, Geraldton demands a high level of engineering precision.

Hamilton By Design supports Geraldton businesses and project teams with an integrated workflow of 3D LiDAR laser scanning, 3D CAD modelling, mechanical & structural engineering, and fabrication-ready drafting. For brownfield upgrades, shutdowns, port expansions, industrial maintenance or new plant installations, our engineer-led scanning and modelling process removes guesswork and delivers millimetre-accurate confidence.

Why Geraldton Is Unique — and Why Precision Matters Here

Geraldton’s industrial environment brings a mix of coastal, agricultural, mining-supply and port-driven challenges:

A major deep-water port exporting grain, mineral sands, iron ore and project cargo.
Salt, wind and marine exposure, creating elevated corrosion risk and structural degradation over time.
Rapid industrial expansion, including renewables, hydrogen developments and logistics infrastructure.
Heavy agricultural processing and storage facilities requiring accurate as-built documentation.
Fabrication workshops and marine-repair industries that depend on precise measurements for fit-ups and installations.

This combination makes high-accuracy digital engineering essential for safe planning, fabrication, installation and long-term maintenance.

3D LiDAR Laser Scanning — The Foundation of Reliable Engineering in Geraldton

Hamilton By Design uses engineering-grade LiDAR scanning to capture highly accurate as-built conditions for industrial assets, port infrastructure, conveyor systems, structural steel, storage facilities, platforms, marine installations and complex brownfield environments.

Our scans deliver:

Millimetre-accurate digital geometry
Complete capture of steelwork, conveyors, chutes, tanks, pipework and machinery layouts
Safer data collection with minimal site intrusion
Faster planning for shutdowns, retrofits and upgrades
Confidence that fabrication will fit the first time

Learn more about our scanning services here:
3D Laser Scanning

For Geraldton’s industrial clients, accurate scanning reduces rework, speeds up fabrication, and provides a digital asset model that supports efficient maintenance.

3D CAD Modelling — Turning Reality Into Reliable Engineering Data

Once scanned, your site is modelled into intelligent, workable 3D CAD assemblies. This provides a digital foundation for engineering, fabrication and installation.

Our modelling services include:

Mechanical & structural 3D assemblies
Conveyor, chute, tank, pump, and pipeline models
General arrangement (GA) drawings
Fabrication drawings, isometrics and BOMs
Clash detection & layout optimisation
Brownfield upgrade planning

Geraldton industries — from port operations to fabrication yards — benefit significantly from models that depict true as-built conditions, not assumptions.

Explore our modelling capabilities here:
3D CAD Modelling

Engineering & FEA — Built for Coastal, Industrial & High-Load Environments

Geraldton’s industrial landscape involves high wind loads, marine influence, heavy equipment and load-bearing structures. Hamilton By Design provides engineering services tailored to these realities.

Our engineering support includes:

Mechanical design & optimisation
Structural assessments & remediation design
Conveyor, chute & materials-handling engineering
Equipment layout & access improvements
Pressure vessel & tank evaluations
FEA stress, fatigue, modal & thermal assessments

See our FEA capabilities here:
FEA Capabilities

Drafting Services — Clear, Build-Ready Documentation

Fabrication-ready documentation ensures your project can move from design to manufacture seamlessly.

Our drafting services include:

Detailed workshop drawings
Isometric piping & mechanical drawings
Structural detailing
Marked-up modification drawings
As-built drawing creation and revision

Explore drafting services here:
Drafting Services

With Geraldton’s strong fabrication and engineering-support sector, having accurate, clean and consistent drawings is critical for productivity and installation success.

How Geraldton Projects Benefit From Hamilton By Design

Whether you’re upgrading port conveyors, modifying grain-handling infrastructure, refurbishing marine-exposed structures, or installing new process equipment, our end-to-end workflow provides:

One source of truth from scan → model → engineering → drafting
Reduced shutdown time
Minimal rework due to clash-free, accurate designs
Improved safety with less manual measurement in hazardous areas
Faster fabrication through precise digital inputs

From Beresford to Narngulu to the Geraldton Port precinct, our engineering team supports projects of all scales with industry-leading accuracy and speed.

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11 December 202511 December 2025

3D Scanning Engineering Simplified in Pilbara

The Pilbara is one of the most iconic industrial landscapes in the world — a region defined by massive iron ore operations, rail networks, export ports, processing hubs, remote infrastructure, and some of the toughest working conditions in Australia. With extreme heat, red-dust environments, heavy-duty machinery and 24-hour production schedules, engineering in the Pilbara demands precision, reliability and speed.

Hamilton By Design supports Pilbara projects with an end-to-end workflow that integrates 3D LiDAR laser scanning, 3D CAD modelling, engineering assessments, FEA analysis, and fabrication-ready drafting — all engineered to remove guesswork and simplify brownfield and greenfield upgrades in high-risk, high-value industrial environments.

Whether you work across Port Hedland, Karratha, Newman, Tom Price, Dampier, Paraburdoo, or remote mine-site operations, our engineering-led scanning workflow delivers the clarity you need to design, install and maintain plant assets with confidence.

Why the Pilbara Is Unique for Engineering Projects

The Pilbara stands apart from nearly every other region in the country. Its uniqueness comes from:

1. Mega-scale iron ore operations

With some of the world’s largest open-cut mines and export volumes, the Pilbara’s infrastructure is constantly expanding — conveyors, stackers, reclaimers, crushers, screening plants, workshops, fuel systems, and ore-handling upgrades all require high-accuracy as-builts for planning and design.

2. Remote location and logistics constraints

Downtime is expensive and mobilisations are even more so. Every hour counts. Designs need to be right the first time — which is where digital capture and modelling become essential.

3. Harsh environmental conditions

Extreme temperatures, abrasive dust, corrosion, wind loads and environmental regulations make compliance, materials selection, and structural design more complex.

4. Brownfield complexity

Most Pilbara sites have decades of modifications layered over the original design. This means undocumented interferences, alignment issues, legacy steelwork, variable foundations and inconsistent documentation that require precise digital capture.

5. High-risk, high-value assets

Bulk-handling machines, load-out systems, transfer towers, and ore-processing plant modules rely on millimetre-accurate measurement for safe and compliant upgrades.

These factors make 3D laser scanning + engineering modelling the most reliable way to plan and execute upgrades across Pilbara operations.

High-Accuracy 3D LiDAR Scanning for Mining & Processing

Hamilton By Design captures full site geometry using engineering-grade LiDAR scanners to deliver millimetre-accurate as-built data.

Our scanning is ideal for:

conveyors, transfer towers & trestles
stackers, reclaimers, crushers & screening plants
train load-out facilities
pipe racks, pump systems & mechanical services
structural platforms, handrails & walkways
workshop fit-outs and maintenance bays
port and marine bulk-handling infrastructure

Explore our service:
3D Laser Scanning

The resulting point cloud forms a digital twin of your facility — enabling precise design checks, measuring, clash detection and upgrade planning without repeated site visits.

Turning Scans Into Engineering-Ready Models

Once captured, your point cloud is converted into clean, accurate 3D CAD models suitable for mechanical, structural and fabrication workflows.

Learn more:
3D CAD Modelling

Our models support:

brownfield plant upgrades
conveyor realignment or replacement
new steelwork tie-ins
equipment skid design & integration
pump, piping & mechanical layouts
layout optimisation & access compliance

This level of detail dramatically reduces installation risk and fabrication rework — critical in remote regions like the Pilbara.

Engineering & FEA for Heavy Industry

The Pilbara’s large-scale machinery and structures require robust engineering verification. Hamilton By Design provides mechanical and structural assessments backed by advanced simulation.

View capabilities:
FEA Capabilities

Our engineering services include:

linear static stress checks
fatigue assessment
buckling & stability analysis
thermal, vibration and modal analysis
pressure vessel & structural load evaluation
mechanical failure diagnostics

From bucket-wheel components to crusher supports, conveyor gantries and mobile equipment frames — we ensure your assets meet compliance and performance requirements.

Fabrication-Ready Drafting for Pilbara Projects

Clear drawings reduce installation errors, accelerate shutdown work, and streamline fabrication.

Explore drafting services:
Drafting

We deliver:

GA drawings
detailed fabrication drawings
weld maps & BOMs
workshop documentation
isometric piping & ducting drawings
tender & construction documentation

Our drafting aligns with your fabricator’s preferences, ensuring clean workflow from modelling to installation.

Why Pilbara Projects Choose Hamilton By Design

Hamilton By Design offers a fully integrated engineering workflow:

3D LiDAR Scan – capture the real-world geometry
Point-Cloud Processing – aligned, registered and clean
Engineering 3D Models – accurate and clash-checked
Engineering Analysis – FEA, structural checks, mechanical assessment
Fabrication Drafting – ready for workshop, procurement or installation
Ongoing Support – modifications, design updates, QA records

This leads to:

fewer shutdown delays
reduced on-site measuring
safer brownfield engineering
faster design cycles
less fabrication error
significant cost savings on remote-site mobilisation

Supporting Pilbara Iron Ore, Energy, Infrastructure & Export Projects

Hamilton By Design supports work across:

Rio Tinto, BHP, FMG & Roy Hill operations
processing plants & ore-handling facilities
rail infrastructure and load-out systems
marine and port bulk-handling terminals
camp facilities, utilities & remote plants
structural and mechanical maintenance upgrades

From Newman to Port Hedland, Dampier, Karratha, Christmas Creek, Tom Price and beyond — our engineering-led scanning capability simplifies complex projects in one of Australia’s most demanding industrial environments.

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10 December 202510 December 2025

Townsville’s Industrial Frontier

Townsville’s Industrial Frontier — How 3D LiDAR, Digital Engineering and Modern Drafting Are Powering North Queensland Projects

Townsville is much more than a tropical coastal city — it’s the beating industrial heart of Northern Australia. As the largest urban centre north of the Sunshine Coast, Townsville connects mining, maritime, defence, manufacturing and export logistics in a way few other regional centres can.

With rapid growth across the port, military infrastructure, mining-supply networks, marine services and export facilities, the region demands precision, reliability and future-ready engineering solutions. That’s where Hamilton By Design steps in — offering tailored 3D LiDAR laser scanning, comprehensive mechanical and structural engineering, advanced 3D modelling, and fabrication-ready drafting to meet Townsville’s unique and complex needs.

If you’re planning a warehouse expansion, a plant upgrade, port logistics facility, or maintenance overhaul — we give you data-driven confidence from day one.

Why Townsville Needs Digital Engineering & 3D Scanning

Townsville stands out among Australian regional cities because of its diverse economy and heavy industrial footprint:

It hosts one of Australia’s busiest multi-cargo seaports — Port of Townsville — handling minerals, metals, bulk exports, container freight, and supporting exports from Western and North-West Queensland mining regions.
It supports major mining supply chains, metal-refining operations and logistics infrastructure across the region.
It hosts the largest defence garrison in northern Australia — Lavarack Barracks — plus associated military, infrastructure and support-facility requirements.
Townsville’s urban and industrial centre sits beside a sensitive coastal environment, with proximity to the Great Barrier Reef and marine ecosystems — meaning infrastructure must often balance heavy-duty utility with environmental and spatial constraints.

This mix of heavy industry, maritime logistics, defence requirements, and environmental sensitivity demands more than standard surveys — it needs digital accuracy, thorough engineering, careful planning and future-ready documentation.

3D LiDAR Laser Scanning — The Foundation of High-Integrity Projects

When dealing with port terminals, refinery installations, mining supply warehouses, defence facilities, or heavy-machinery workshops, inaccurate site measurements can be costly — leading to misaligned equipment, interference, regulation compliance risks, fabrication errors or rework.

At Hamilton By Design, our 3D LiDAR laser scanning service captures full as-built environments with high precision, including:

structural steel, supports and framing
complex pipework, conveyors, fittings
terrain, civil features and existing utilities
machinery layout, clearances, and tie-in points

The result: a complete, millimetre-accurate digital record of your site’s geometry — ideal for analysis, retrofits, expansions or maintenance.

Discover our full capabilities here: 3D Laser Scanning
https://www.hamiltonbydesign.com.au/home/3d-lidar-scanning-digital-quality-assurance/3d-laser-scanning/

For Townsville clients, this means fewer shutdowns, safer project planning, faster fabrication, and minimized risk of unexpected clashes or construction rework.

From Point Cloud to Precision — 3D Modelling, Drafting & Engineering

Once the scan is complete and point-cloud data processed, we build intelligent 3D models and fabrication-ready documentation:

mechanical and structural CAD models (existing and proposed)
general arrangement (GA), detailed drawings, isometrics and BOMs
clash detection and interference checking before fabrication or retrofit
layout optimisation for workflow, maintenance access, and safety compliance
digital archives for future maintenance or expansion

For heavy-duty environments such as port facilities, refineries, warehouses, defence-related infrastructure or mining supply workshops — having accurate 3D models eliminates costly guesswork and supports efficient execution.

In short: we give you digital twins, not just drawings.

Engineering Support for Townsville’s Key Industries

Townsville’s industrial profile spans mining, export logistics, maritime, defence, metals processing and large-scale fabrication — each with its own engineering demands.

Hamilton By Design offers:

structural assessments (platforms, supports, frames, foundations) for retrofits or new installations
mechanical layout and alignment design (conveyors, cranes, heavy equipment, storage systems)
load, stress and fatigue analysis (FEA) for steelwork, pressure equipment, supports or chassis
piping, chute or conveyor design and re-routing for upgrading plants or refineries
compliance documentation and fabrication-ready drawings ready for procurement, tendering or regulatory approval

Whether you’re upgrading a shipping-container terminal, expanding a warehouse, installing new refinery modules, building maintenance workshops for mining machinery, or constructing support facilities for defence or export operations — our engineering-led workflow ensures you build right the first time.

Streamlined Workflow — From Scan to Delivery, One Trusted Partner

One common problem for regional projects is coordinating between multiple service providers — surveyors, draftspeople, engineers, fabricators — which often leads to miscommunication, delays, or misaligned deliverables.

Hamilton By Design offers a single-source bundle:

3D LiDAR site scan
Point-cloud data processing and registration
3D CAD modelling
Engineering assessment and design
Fabrication-ready drafting and documentation
Digital QA and delivery

We handle everything — you get consistent quality, clear responsibility, and projects that move smoothly from concept to construction.

Real-World Use Cases for Townsville Clients

Port Expansion & Upgrade Projects

As the Port of Townsville expands and modernises to handle larger cargo, new cranes, heavier loads and increased throughput, accurate 3D scans and structural/foundation assessments are critical. Our scanning + modelling + design services ensure new installations fit existing layouts perfectly, avoid clashes, and meet structural integrity and safety standards.

Mining Supply, Maintenance & Fabrication Workshops

Supporting the North-West mining region means heavy machinery maintenance, parts fabrication, and workshop upgrades. Accurate laser scans and CAD models allow fabricators to pre-validate alignments, clearances, and fit-outs before steel is cut.

Defence Infrastructure & Facility Upgrades

With the presence of large defence bases and logistics hubs, upgrades, extensions, or refurbishments often demand strict compliance and precise structural layouts. Our end-to-end digital engineering approach ensures regulations, load requirements, and integration requirements are met without surprises.

Industrial Refineries & Metals Processing Plants

Whether it’s zinc, copper or other metals processing, heavy-duty installations often include pipework, structural supports, conveyors, and complex layout constraints — perfect candidates for digital twin creation, clash detection, and fabrication-ready design.

Multi-use Warehouses, Logistics Hubs & Fabrication Yards

As Townsville grows, so does demand for supply-chain infrastructure. For logistics hubs and fabrication yards, accurate site scans and 3D planning streamline material flow, design logistics, safety compliance, and maintenance scheduling.

Why Townsville — and Hamilton By Design — Is a Winning Combination

Townsville is uniquely placed as a northern Australia hub that supports mining, port exports, defence, fabrication, metallurgy and logistics — all under a tropical but manageable climate. That diversity means clients across sectors demand precision, reliability and best-practice engineering.

Hamilton By Design is ready to deliver just that — combining modern 3D laser scanning, smart CAD modelling, thorough engineering discipline and fabrication-ready design in one seamless package.

If you’re operating in Townsville or servicing projects across North Queensland — whether mining supply, port infrastructure, fabrication yards, defence facilities, metal processing, or logistics hubs — we’re equipped to support your next project, reduce risk, and deliver results on time and on spec.

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2 November 202528 November 2025

Mechanical Engineering Sydney: Why Local Expertise Beats Offshore Design

When Local Knowledge Makes All the Difference

Across Sydney, the Central Coast, and Newcastle, more contractors and plant managers are discovering a simple truth — offshore engineering might look cost-effective, but local expertise delivers better outcomes every time.

When drawings don’t meet Australian Standards, materials can’t be sourced locally, or site measurements are off by just a few millimetres, “cheap” design quickly becomes expensive rework.

That’s why businesses across NSW are turning to Hamilton By Design — a Sydney-based mechanical engineering practice that understands how to bridge design and construction through real-world experience, compliance, and precision.

Illustrated infographic showing Hamilton By Design’s 3D scanning workflow in Sydney, including onsite LiDAR scanning, point-cloud processing, SolidWorks modelling, and local fabrication, with Sydney landmarks in the background

Built for Australia, Not Adapted for It

Engineering design isn’t universal.
Sydney’s environment, industry, and regulatory framework are unique — from local council approval requirements to the coastal conditions that affect corrosion and material selection.

At Hamilton By Design, our drawings and models are created with Australian Standards front and centre. We design for:

AS 4100 (Steel Structures)
AS 3990 (Mechanical Equipment Design)
AS 1657 (Walkways, Platforms & Stairs)
AS 4991 (Lifting Devices)
AS 4024 (Machine Safety)

Designing to these standards means your project moves faster through approvals, fabrication, and certification — with no surprises down the track.

Offshore designers often mean well, but they don’t work within these standards every day.
A single misinterpreted load case or welding symbol can mean days of rework on site.
A local engineer gets it right the first time.

Drawings That Fabricators Love

A good drawing doesn’t just look professional — it saves hours in the workshop.
Hamilton By Design creates fabrication drawings that make sense to the people who use them.

We think like tradespeople because we’ve been tradespeople.
Our background in fitting, machining, and CNC fabrication ensures every detail — from weld prep to bolt clearances — reflects how the job will actually be built.

That means fewer questions from the shop floor, cleaner fit-ups, and faster turnaround from fabrication to installation.

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

Local Materials. Local Supply Chains. Fewer Delays.

Sydney’s fabrication and construction industry runs on locally available materials — from Bluescope steel to Bisalloy plate.
When offshore drawings specify unavailable materials or imperial sizes, fabrication stalls.

Our team specifies components, sections, and finishes that Sydney and Central Coast suppliers actually stock.
That reduces lead times, avoids substitutions, and keeps projects moving.

We also design with Sydney’s coastal environment in mind — using corrosion-resistant coatings, sealants, and fasteners suitable for marine-influenced locations like Parramatta, Botany, and Gosford.

Designed to Fit the Site — The First Time

It’s one thing to design in CAD; it’s another to make it fit in the field.
Sydney worksites can be complex — restricted access, uneven terrain, or legacy structures that don’t match the old drawings.

That’s why Hamilton By Design uses 3D scanning and LiDAR technology to capture accurate site data before design begins.
We integrate those scans directly into SolidWorks, building models that align with real-world geometry.

Every bracket, pipe run, and platform is verified in 3D before fabrication starts — ensuring a smooth installation with no rework.

Sydney Expertise with Regional Reach

We proudly serve clients across Sydney, Newcastle, and the Central Coast, working with builders, maintenance contractors, and fabrication workshops who value local knowledge.

Our typical projects include:

Plant upgrades and retrofits in brownfield sites.
Fabrication drawing packages for chutes, platforms, and pipework.
Reverse engineering from worn or obsolete components.
3D scanning for as-built documentation.
Finite Element Analysis (FEA) for structural verification.

Every project benefits from our combined trade and engineering background — practical solutions grounded in decades of hands-on experience.

Smooth Communication. Real Accountability.

When you work with a local engineer, you’re not waiting overnight for an email response from another time zone.
You can pick up the phone, meet on site, or review models in person.

That direct collaboration saves time, reduces misunderstandings, and builds confidence between all stakeholders — engineers, fabricators, and project managers alike.

At Hamilton By Design, we value clear communication. You’ll know exactly what stage your project is at, what we’re designing, and how it aligns with your goals.

The Real Cost of Offshore Design

Offshore pricing often looks appealing — until you factor in delays, non-compliance, or fabrication mismatches.
Here’s what typically happens when projects cut corners:

Challenge	Offshore Design	Local Expertise (Hamilton By Design)
Standards & Codes	Often missed or misapplied	Fully compliant with AS/NZS standards
Material Availability	Specified incorrectly	Designed for Australian supply chains
Communication	Delayed and unclear	Direct, same-day response
Site Understanding	Based on photos	Based on 3D scans and site visits
Rework Risk	High	Minimal – verified before fabrication

When you calculate the true cost — lost time, rework, freight, and approval delays — offshore design rarely saves money.

Technician using a FARO 3D laser scanner and tablet to capture a construction site for digital modelling, with 3DEXPERIENCE and SolidWorks logos shown on the side

Real Example: Central Coast Fabrication Success

A local contractor recently engaged Hamilton By Design to assist with a pump platform upgrade on the Central Coast.
Previous offshore drawings had mismatched hole patterns and unsupported loads.

We performed a quick 3D scan, remodelled the assembly in SolidWorks, and issued fabrication drawings ready for workshop production.
The new structure was installed without modification, saving the client several days of rework and earning rapid certifier approval.

That’s what local insight delivers — certainty and speed.

Why Choose a Sydney-Based Engineer

Sydney projects move quickly.
They need partners who can respond fast, understand the regulations, and coordinate seamlessly with site teams.

Hamilton By Design offers:
✅ Over 25 years of trade and design experience
✅ SolidWorks and FEA capability since 2011
✅ 3D scanning and as-built modelling for existing plants
✅ Fabrication drawings built for local workshops
✅ Practical designs created by people who’ve worked in the field

We’re based in Sydney and proud to support regional clients in Newcastle, the Central Coast, and Western Sydney.

Talk to a Sydney-Based Engineer Who’s Worked in the Field

Every project is a partnership — and great results come from working with people who understand your environment.
Hamilton By Design isn’t just another design service; we’re your local mechanical engineering partner — practical, responsive, and invested in your success.

If you’re planning a plant upgrade, mechanical installation, or fabrication project, let’s make sure your drawings are done right the first time.

Banner displaying Hamilton By Design alongside partner and technology logos including SolidWorks, UTS, Dassault Systèmes 3DEXPERIENCE, and FARO, with the text ‘3D Scanning 3D Modelling’ and website www.hamiltonbydesign.com.au

👉 Talk to a Sydney-based engineer who’s worked in the field.
Visit www.hamiltonbydesign.com.au or contact us today to discuss your next project.

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.