Category: 3D Cad Design

Professional 3D CAD design services for mechanical, structural and industrial projects. Hamilton By Design delivers accurate models, fabrication-ready drawings, FEA-supported designs and fully engineered digital solutions for mining, construction and manufacturing.

Posted on

3D Scanning Engineering in Tamworth

3D Scanning in Tamworth

Tamworth is one of the most important inland cities in New South Wales — a defence hub, agricultural powerhouse, logistics gateway and regional manufacturing centre. As the city continues to grow its industrial capability and upgrade infrastructure across defence, agriculture, transport, civil works and fabrication sectors, the need for modern engineering tools has never been stronger.

Hamilton By Design supports Wagga Wagga with 3D LiDAR scanning, mechanical and structural engineering, 3D CAD modelling, FEA simulation, and fabrication-ready drafting, delivering a complete digital engineering workflow from first site scan through to final drawings.

Whether you’re upgrading a defence facility, redesigning an agricultural processing line, documenting a logistics depot, modernising a workshop or preparing a brownfield structure for retrofit — our engineering-led approach gives you the confidence to build accurately and efficiently.

This article outlines how 3D scanning and digital engineering transform project outcomes in the Riverina region.

Why Wagga Wagga Is a Prime Location for 3D Scanning & Engineering

1. Dual Defence Bases — RAAF Base Wagga + Kapooka Army Recruit Training Centre

Wagga is one of the only regional cities in Australia hosting two major defence establishments. Defence projects in the city require high levels of precision, compliance, digital documentation and engineering accuracy — all supported by modern scanning and modelling tools.

2. Agricultural Powerhouse of the Riverina

Wagga supports one of the largest inland agricultural regions in the country. Facilities requiring regular upgrades include:

  • pump stations
  • irrigation systems
  • silos and grain-handling plants
  • processing equipment
  • machinery sheds
  • livestock and rural infrastructure

These sites often require accurate surveying, retrofit engineering and digital as-built documentation — tasks perfectly suited to LiDAR scanning.

3. A Logistics, Freight & Manufacturing Hub

At the junction of the Sturt Highway, Olympic Highway and major freight routes, Wagga Wagga serves as:

  • a key transport centre
  • a manufacturing and fabrication district
  • a support hub for mining, defence, agriculture and civil construction

Accurate models, digital scans and engineering documentation help streamline upgrades, expansions and fabrication work across these sectors.

4. The Murrumbidgee River — Civil & Hydrology Challenges

Riverside assets, bridges, levees, drainage systems and public structures require constant improvement. LiDAR scanning and digital modelling make civil engineering more predictable, safer, and easier to plan.

3D LiDAR Laser Scanning — The Foundation of Accurate Engineering

Hamilton By Design provides high-accuracy 3D LiDAR scanning for buildings, industrial facilities, workshops, civil structures and brownfield environments. We capture millions of precise data points per second, producing millimetre-accurate digital twins used for engineering, modelling and drafting.

Our scanning service covers:

  • mechanical equipment
  • structural steel, platforms, walkways
  • pipework and tanks
  • sheds, workshops, farm facilities
  • buildings (internal and external)
  • terrain and drainage
  • defence and civil infrastructure

Learn more about our capabilities:
3D Laser Scanning

Benefits of 3D Scanning for Wagga Wagga Projects

  • Accurate as-built documentation
  • Reduced shutdown times
  • Less rework during fabrication
  • Better coordination between contractors
  • Improved safety (minimal manual measurement)
  • Faster engineering and design turnaround
  • Reliable models for upgrades and retrofits

In a city with ageing structures, brownfield facilities and diverse industrial activity, digital scanning creates clarity where traditional measurement falls short.

3D CAD Modelling — Turning Scans into Intelligent Engineering Models

Once scanning is complete, Hamilton By Design transforms point-cloud data into detailed 3D CAD models, structural layouts and mechanical assemblies.

We model:

  • agricultural processing lines
  • pump systems and pipework
  • conveyors and mechanical equipment
  • structural frames, platforms and stairs
  • fabrication-ready steel structures
  • building layouts for redevelopment
  • defence facility upgrades

Our modelling supports precise engineering decision-making, alignment checks, clash detection and well-structured documentation.

Explore our modelling services:
3D CAD Modelling

FEA Analysis — Engineering Confidence for Complex Projects

Many Wagga Wagga projects involve load-bearing structures, moving equipment, mechanical stress, fatigue risks or compliance requirements. Hamilton By Design performs Finite Element Analysis (FEA) to validate the safety, performance and reliability of your designs.

We analyse:

  • structural frames
  • mechanical components
  • tanks, brackets and supports
  • agricultural machinery
  • access platforms and retrofits
  • equipment subjected to vibration, pressure or fatigue

This ensures every design is safe, compliant and ready for construction.

Learn more about our simulation capability:
FEA Capabilities

(If you’d like, I can correct the FEA URL if this is not the intended final link — just tell me.)

Drafting Services — Fabrication-Ready, Clear & Accurate

Wagga Wagga’s industrial and agricultural workshops depend on drawings that are:

  • clear
  • accurate
  • fabrication-ready
  • compliant
  • easily interpreted by boilermakers, contractors and site crews

Hamilton By Design provides:

  • general arrangement drawings
  • fabrication detail drawings
  • isometrics and BOMs
  • structural drafting
  • mechanical drafting
  • P&ID updates
  • revision control and QA documentation

View our drafting services here:
Drafting

All drafting is generated from verified scan data and validated engineering models, ensuring first-time fit-up and reduced fabrication risk.

Where Hamilton By Design Adds Value in Wagga Wagga

1. Defence Projects and Facility Upgrades

Perfect for:

  • as-built modelling
  • mechanical/structural modifications
  • digital site capture
  • designing safe access systems
  • maintaining compliance records

2. Agricultural Infrastructure & Processing Plants

Ideal for:

  • pump stations
  • grain conveyors
  • silos and storage systems
  • livestock handling systems
  • machinery retrofits

3. Fabrication & Manufacturing Workshops

Supporting:

  • structural steel
  • machine frames
  • industrial components
  • site installations
  • complex fit-ups

4. Civil & Council Infrastructure

Including:

  • bridges
  • footpaths
  • drainage networks
  • public buildings
  • river-adjacent assets

5. Commercial & Industrial Redevelopment

Great for:

  • internal building scans
  • renovation planning
  • layout optimisation
  • service routing

End-to-End Workflow — One Team, One Source of Accountability

Hamilton By Design ensures a smooth, unified digital engineering pipeline:

  1. 3D LiDAR Scan
  2. Point Cloud Registration & QA
  3. 3D CAD Modelling
  4. FEA Engineering Analysis
  5. Drafting & Fabrication Packages
  6. Digital QA & Final Documentation

No multi-contractor confusion.
No inconsistencies.
Just a clean, accurate workflow from measurement to construction.

Hamilton By Design logo displayed on a blue tilted rectangle with a grey gradient background

Wagga Wagga’s Future Is Digital — And Hamilton By Design Is Ready

With its growing defence, agricultural, logistics and manufacturing sectors, Wagga Wagga needs modern engineering methods to keep pace with development. Digital scanning, modelling, engineering analysis and drafting streamline the entire project lifecycle, reducing rework and increasing reliability.

Hamilton By Design delivers:

  • precision 3D scanning
  • engineering-grade modelling
  • validated FEA simulation
  • clear drafting
  • accurate, build-ready documentation
  • end-to-end project confidence

Whether your project is a shed, a defence facility, a processing plant, a workshop or a civil structure — we are ready to support it from concept through to fabrication.

Posted on

3D Scanning for Gladstone

Gladstone’s Industrial Powerhouse: How 3D LiDAR Scanning, Engineering & Digital Modelling Are Transforming CQ Projects

Gladstone is unlike any other regional city in Australia. It is a true industrial powerhouse — home to the country’s largest multicommodity port, three LNG mega-plants, major alumina refineries, a huge aluminium smelter, power stations, chemical facilities, cement production and a constant cycle of shutdown and maintenance projects. If you work in engineering, fabrication, construction or heavy industry, Gladstone represents one of the most complex, interesting and opportunity-rich environments in the country.

At Hamilton By Design, we bring engineering-grade 3D LiDAR laser scanning, mechanical and structural engineering, 3D modelling and fabrication-ready drafting to support the precision required in this region. With so many brownfield assets, tight shutdown windows, high-risk environments and complex layouts, Gladstone’s industrial clients rely on accurate data and robust engineering to ensure safe, efficient and reliable project outcomes.

This article explores why Gladstone is such a unique engineering ecosystem — and how modern digital tools are improving plant upgrades, maintenance, fabrication, installation and long-term reliability.

Why Gladstone Is One of Australia’s Most Unique Engineering Environments

Gladstone’s industrial landscape is the result of decades of strategic investment and natural geographic advantages. No other regional city has this density of heavy processing facilities, export terminals and energy infrastructure in one place.

1. A Mega-Scale Industrial Port

The Port of Gladstone is Queensland’s largest multicommodity port, handling:

  • coal
  • LNG
  • alumina
  • aluminium
  • cement
  • bulk chemicals
  • mineral products
  • general and containerised freight

The port’s footprint includes conveyors, loading towers, wharf structures, pipelines, tanks, gantries and processing equipment — much of which requires ongoing scanning, modelling and engineering to maintain safe, efficient operations.

2. Three LNG Plants on Curtis Island

Gladstone is home to Australia’s only cluster of three major LNG export facilities, each containing:

  • pressure vessels
  • cryogenic tanks
  • kilometres of pipe racks
  • modularised process trains
  • large structural steel assemblies
  • jetties and marine loading arms

This creates unparalleled demand for digital engineering, scanning and verification.

3. A Complete Heavy-Industry Chain

Few cities have such an interconnected set of process plants:

  • Queensland Alumina Limited (QAL)
  • Rio Tinto Yarwun Alumina Refinery
  • Boyne Aluminium Smelter
  • NRG and other power facilities
  • Cement Australia

Each site requires constant:

  • shutdown planning
  • precise measurement
  • design modifications
  • structural integrity checks
  • digital as-builts
  • engineering documentation

This continuous workload makes Gladstone one of the biggest users of LiDAR scanning and mechanical/structural engineering in Australia.

4. The City Runs on Projects

Gladstone’s industrial sector operates year-round:

  • maintenance shutdowns
  • brownfield upgrades
  • fabrication campaigns
  • equipment replacements
  • process improvements

Accurate spatial data is not optional — it is essential for avoiding clashes, rework and costly delays.

3D LiDAR Laser Scanning — Reducing Risk in Gladstone’s Complex Industrial Plants

In a brownfield environment like Gladstone, complexity is the norm:

  • crowded pipe racks
  • confined spaces
  • undocumented modifications
  • ageing platforms and walkways
  • shifting alignment over time
  • corrosion and wear
  • intricate mechanical layouts

Traditional surveying simply cannot capture enough detail to support safe and efficient upgrades.

That’s why Hamilton By Design delivers engineering-grade 3D LiDAR scanning, capturing entire facilities with millimetre-level accuracy.

Our scanning provides high-resolution digital data for:

  • refineries
  • smelters
  • LNG plants
  • conveyors and materials handling
  • marine loading facilities
  • tanks and pressure systems
  • structural steel
  • civil and terrain modelling

The result is a precise, true-to-life digital environment used for design, clash detection, structural checks, fabrication planning and QA.

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

For Gladstone, LiDAR scanning means:

  • fewer shutdown delays
  • safer engineering access
  • accurate tie-in points
  • reduced rework during installation
  • better fabrication accuracy
  • confidence in brownfield modifications

In an environment where time = money, this technology is transformative.

3D Modelling & Drafting — Turning Complexity into Clarity

Once the scan data is captured, Hamilton By Design converts it into structured 3D CAD models and fabrication-ready drawings. This process is essential in Gladstone’s industrial context, where upgrades often occur inside densely packed areas with zero room for error.

We deliver:

  • SolidWorks models of equipment, structures and layouts
  • general arrangement (GA) drawings
  • detailed fabrication drawings
  • piping/isometric drawings
  • platform, handrail and structural packages
  • alignment and clearance analysis
  • digital QA documentation

For LNG, alumina, port and refinery clients, accurate 3D modelling prevents clashes, supports tender and fabrication packages, and provides a reliable digital reference long after the project is complete.

Mechanical & Structural Engineering for Gladstone’s Heavy Industry

Gladstone’s operating environment requires engineering that is:

  • robust
  • precise
  • compliant
  • optimised for reliability
  • grounded in real-world site conditions

Hamilton By Design provides mechanical and structural engineering for:

  • plant upgrades and retrofits
  • conveyor and materials handling systems
  • support structures, frames and platforms
  • tanks, piping and pressure systems
  • fatigue, stress and load assessments
  • access and maintenance design
  • lifting, mounting and replacement systems

Our engineer-led approach ensures all designs are supported by verified data from LiDAR scanning and validated using modern analysis tools.

Where We Add the Most Value in Gladstone

1. Refinery & Smelter Shutdown Engineering

Scanning + modelling reduces:

  • tie-in errors
  • mismatch in fabricated steel
  • shutdown overruns
  • safety risks

2. LNG Plant Modifications & Brownfield Upgrades

LiDAR gives accurate data for:

  • pipe rerouting
  • structural steel changes
  • equipment replacement
  • modular installation

3. Port Facilities & Marine Loading Infrastructure

We support:

  • conveyor structures
  • wharf upgrades
  • loadout systems
  • marine walkways and assets

4. Fabrication & Workshop Support

Local fabricators benefit from:

  • accurate shop drawings
  • digital QA
  • validated steel cutting
  • correct fit-up on first installation

5. Civil & Terrain Modelling

For foundations, tank pads, laydown areas and access roads.

End-to-End Accountability: Scan → Model → Engineer → Draft → Deliver

Gladstone’s project environment involves many contractors — which can lead to miscommunication. Hamilton By Design solves this with a unified workflow:

  1. 3D LiDAR Scan
  2. Point Cloud Registration
  3. 3D CAD Modelling
  4. Mechanical & Structural Engineering
  5. Fabrication-Ready Drafting
  6. Digital QA & Documentation

One team. One process. One accountable source.
Minimal rework. Maximum clarity.

Hamilton By Design logo displayed on a blue tilted rectangle with a grey gradient background

Gladstone’s Future Is Heavy Industry + Digital Precision — And We’re Ready

With rising LNG activity, alumina growth, port expansions, hydrogen projects and ongoing shutdowns, Gladstone is entering a new era of industrial development. Accurate data, digital modelling and strong engineering discipline are no longer optional — they are core to safe, efficient and cost-effective project delivery.

Hamilton By Design is here to support Gladstone with:

  • precision 3D LiDAR scanning
  • mechanical & structural engineering
  • 3D modelling and CAD drafting
  • digital project documentation
  • fabrication-ready deliverables

Whether you’re planning a shutdown, designing a new structure, upgrading existing systems or documenting a complex brownfield environment, we help you build with confidence.

Our Clients

Name
Would you like us to arrange a phone consultation for you?
Posted on

SolidWorks Mechanical Design Services

Hero image showing a LiDAR-coloured point-cloud model of an industrial conveyor system on the left transitioning into a detailed SolidWorks 3D CAD model on the right, with the heading ‘SolidWorks Mechanical Design Services’ and a call-to-action button that reads ‘Start Your Project’

SolidWorks Design Services

The Many Faces of Mechanical Design: How SolidWorks Powers Modern Engineering Across Australia

At Hamilton By Design, we see the same pattern every day across mining, heavy industry, manufacturing, and complex brownfield environments: the quality of engineering outcomes depends directly on the quality of the models driving them. And when it comes to mechanical design, SolidWorks remains one of the most capable and versatile platforms on the planet.

From dragline components to sheet metal enclosures, from pressure vessel upgrades to bespoke robotics, SolidWorks enables engineers to turn ideas into precise, fabrication-ready models that reduce rework, eliminate uncertainty, and accelerate project delivery.

Below, we explore the full spectrum of mechanical design disciplines where SolidWorks excels — and how Hamilton By Design uses this capability to deliver accurate, reliable, engineering-grade outcomes across Australia.

Why SolidWorks Remains the Backbone of Mechanical Design

SolidWorks brings together parametric modelling, simulation, large assembly performance, surfacing, sheet metal tools, weldments, routing and visualisation under a single environment. The result is powerful:

✔ Engineering that is data-driven
✔ Models that are precise and fabrication-ready
✔ Assemblies that reflect true site conditions
✔ Designs that respond intelligently to changes
✔ Drawings that follow Australian Standards
✔ Seamless integration with LiDAR-based as-builts

When paired with Hamilton By Design’s LiDAR scanning workflows, SolidWorks becomes an engine for delivering zero-guesswork mechanical design.

Mechanical Design Disciplines Perfectly Suited to SolidWorks Modelling

SolidWorks supports a huge range of engineering tasks. Below is a deep dive into the disciplines where Hamilton By Design deploys it every day.

1. Machine Design: Precision for Moving Systems

SolidWorks is a natural fit for mechanical equipment upgrades and R&D design work, including:

  • Gearboxes, shafts, keys, couplings
  • Linear motion systems and actuators
  • Mechanical linkages, cams and levers
  • Robotic mechanisms
  • Safety guards, enclosures and subframes
  • Automation concept development

Whether we’re modelling a drive assembly for a conveyor or designing a new piece of automated equipment, SolidWorks gives us full control over the mechanics, kinematics, clearances and manufacturability.

2. Structural Mechanical Design: Frames, Platforms & Fabrication

Mining and industrial plants rely heavily on welded structures and access systems. SolidWorks weldments excel at:

  • Platforms, walkways and stair systems
  • Equipment bases, skids and structural frames
  • Gantries, monorails and supports
  • Pipe supports and brackets
  • Structural reinforcements and upgrade scopes

Built-in cut lists, profile libraries and FEA ensure every frame is practical, safe and fabrication-ready.

3. Pressure Vessels, Tanks & Piping Systems

SolidWorks is an ideal tool for pressure-bound components and interconnected plant systems:

  • Tanks, vessels, bins and hoppers
  • Nozzles, flanges, stiffeners and ladders
  • Pipe routing and spooled sections
  • Chute systems, transitions and flow paths
  • Wear liners and maintenance-friendly redesigns

With stress linearisation, buckling analysis and accurate geometry import from LiDAR scans, we ensure designs meet engineering intent and fit up perfectly on site.

4. Sheet Metal: From Light Fabrication to Industrial Ducting

SolidWorks is the industry standard for sheet metal components:

  • Ducting and HVAC transitions
  • Guards, housings and folded enclosures
  • Electrical cabinets
  • Chute panels
  • Laser-cut and folded brackets

Automatic flat patterns and K-factor control mean fewer mistakes at the plasma/laser cutters and more predictable outcomes for fabricators.

5. Heavy Industry & Mining Equipment Modelling

Hamilton By Design’s roots in mining and heavy industry make SolidWorks invaluable for:

  • Conveyor components and guarding
  • Diverter chutes, hoppers and flow-optimised transitions
  • Bucket-wheel reclaimer parts
  • Crusher and screen upgrades
  • Dragline component modelling
  • Structural deformation/realignment scopes

Combined with LiDAR scanning, SolidWorks becomes the tool that eliminates shutdown fit-up problems.

6. Product Design & Industrial Design

SolidWorks’ surfacing and parametric tools are ideal for:

  • Consumer products
  • Power tools and ergonomic items
  • Injection-moulded components
  • Kitchen or appliance prototypes
  • Concept development for early-stage R&D

It supports rapid iterations, rendering, and export for 3D printing.

7. Robotics & Automation Systems

With the rise of automated processing and Industry 4.0, SolidWorks continues to shine in:

  • End effectors
  • Robotic arms and actuators
  • Kinematic studies
  • Sensor housings
  • Concept layouts for automated cells

We frequently pair this with our LiDAR models of existing plants to create automation solutions that genuinely fit the space.

8. Tooling, Jigs & Fixtures

Fabrication and machining rely on accurate tooling, and SolidWorks helps us design:

  • Welding jigs
  • Machining fixtures
  • Assembly tooling
  • Positioning and inspection gauges
  • Drill guides and alignment tooling

Parametric updates make future modifications simple and consistent.

9. Material Handling Systems

Across mining, ports, agriculture and waste facilities, SolidWorks supports:

  • Conveyor layouts
  • Screw and chain conveyors
  • Transfer chute redesigns
  • Feeders, bins and flow systems
  • Skids and support structures

We routinely pair mechanical redesign with simulation, checking wear patterns, stresses and clearances.

10. Reverse Engineering & As-Built Modelling from LiDAR

This is where Hamilton By Design leads the industry.

We scan sites with millimetre-level LiDAR, then rebuild clean parametric models in SolidWorks for:

  • Brownfield upgrades
  • Fit-up verification
  • Clash detection
  • Replacements and like-for-like manufacturing
  • Structural deformation assessments
  • Shutdown planning

It is the combination of LiDAR + engineering + SolidWorks that gives clients complete confidence in their next project.

How Clients Benefit from SolidWorks-Driven Mechanical Design

✔ Reduced rework

✔ Faster shutdown upgrades

✔ Accurate manufacturing drawings

✔ Better communication between engineers, fabricators and site teams

✔ Safer and more predictable installations

✔ Clear, simulation-backed decision-making

From CHPPs to ports, from power stations to manufacturing plants, SolidWorks modelling allows Hamilton By Design to deliver engineering outcomes you can trust.

Hamilton By Design logo displayed on a blue tilted rectangle with a grey gradient background

Partner With Hamilton By Design for SolidWorks Mechanical Design

We support clients across:

  • NSW (Sydney, Newcastle, Central Coast, Hunter Valley)
  • QLD (Bowen Basin, Surat Basin, Mount Isa)
  • WA (Perth, Pilbara)
  • SA, VIC and regional Australia

If your next project needs mechanical accuracy, design certainty or LiDAR-integrated engineering, our team is ready to support you.

Name
You would like to:

Our clients

SolidWorks

3D Laser Scanning

Engineering Projects

Engineering Services

3D Laser Scanning for Engineering

Posted on

3D LiDAR Scanning Solutions Australia: Capturing Engineering-Grade Accuracy for Mining, Industrial & Infrastructure Projects

3D LiDAR scanning has rapidly become one of Australia’s most valuable engineering tools — and for good reason. From mining CHPPs to power stations, manufacturing plants, processing facilities, marine infrastructure, and complex brownfield upgrades, LiDAR delivers accuracy, clarity, and reliability that traditional measurement methods simply can’t match.

Across Australia’s most demanding industrial regions — the Hunter Valley, Bowen Basin, Pilbara, Mount Isa, Central Coast, Sydney, Adelaide, and beyond — Hamilton By Design provides engineering-grade 3D LiDAR scanning, mechanical design, and full digital-engineering workflows that help clients minimise shutdown duration, eliminate rework, and make better decisions.

This page explains what 3D LiDAR scanning is, why it matters, and how it delivers real, measurable benefits to Australian mining, industrial, and manufacturing operations.

What Is 3D LiDAR Scanning?

LiDAR (Light Detection and Ranging) uses laser pulses to measure millions of points per second, capturing the exact geometry of equipment, structures, and environments. The result is a high-resolution point cloud that serves as a digital replica of the asset — precise down to the millimetre.

Hamilton By Design uses FARO engineering-grade scanners delivering:

  • ±1–2 mm accuracy
  • Full-colour point clouds
  • Safe, fast external and internal scanning
  • High-resolution data suitable for mechanical design and fabrication

This accuracy allows us to model steelwork, chutes, conveyors, piping, tanks, equipment frames, building interiors, structural interfaces, and entire wash plants with confidence.

Why Australian Industries Are Turning to LiDAR

Australia’s mining, energy, and industrial sectors face unique pressures:
tight shutdown windows, ageing infrastructure, safety constraints, limited access, and the constant demand for more accurate data.

LiDAR scanning solves these challenges by offering:

1. Fast, Safe, Non-Contact Measurement

No climbing into hazardous areas.
No lengthy tape measurements.
No assumptions.

LiDAR captures everything from a safe distance — ideal for CHPPs, crushing circuits, transfer towers, power stations, and restricted plant rooms.

2. Zero Guesswork in Brownfield Engineering

Brownfield sites are messy. Nothing is straight, square, or built to the original drawing anymore.

With LiDAR:

  • Misalignment is captured
  • Deformation is visible
  • Corrosion and sag are measurable
  • Legacy drawings can be validated or corrected

This drastically reduces design error across upgrades, fabrication, and shutdown works.

3. Millimetre-Accurate 3D Models for Fabrication

After scanning, Hamilton By Design converts the point cloud into:

  • SolidWorks 3D models
  • GA drawings
  • Fabrication drawings
  • DXF profiles
  • Shop-ready detail packs

Fabricators love it because parts fit the first time, and rework is almost eliminated.

4. Better Shutdown Planning

LiDAR scanning provides clear digital visibility of:

  • Access routes
  • Lifting paths
  • Structural constraints
  • Tie-in locations
  • Clash points

This leads to safer, faster, more predictable shutdown execution.

5. Digital Twins for Long-Term Asset Management

A structured point cloud becomes a digital baseline for future planning.
Clients use it for:

  • Condition monitoring
  • Deviation tracking
  • Long-term upgrade planning
  • Documentation for compliance

It builds engineering resilience into the asset lifecycle.

Industries We Support Across Australia

Hamilton By Design delivers LiDAR scanning and mechanical engineering solutions nationwide, supporting:

Mining & Heavy Industry

  • CHPPs
  • Coal handling plants
  • Hard-rock processing facilities
  • Underground & surface operations
  • Conveyors, chutes, crushers, screen houses

Energy & Utilities

  • Power stations
  • Turbine halls
  • Boiler houses
  • Substations
  • Cooling water systems

Manufacturing & Industrial

  • Plants and factories
  • Production lines
  • Warehouses
  • Material-handling systems

Data Centres & Infrastructure

  • Fit-out scans
  • MEP coordination
  • Expansion planning
  • Brownfield integration

Wherever precision and clarity are required, LiDAR scanning adds value.

Our Digital Engineering Workflow

Hamilton By Design integrates LiDAR scanning into a full project lifecycle:

  1. On-site LiDAR scan using FARO engineering-grade equipment
  2. Processing in FARO Scene to create a clean, structured point cloud
  3. Import into SolidWorks for modelling of required geometry
  4. 3D modelling & mechanical design
  5. Clash detection & feasibility checks
  6. 3DEXPERIENCE reviews with clients
  7. Fabrication drawings, DXF files, and shop packs
  8. Handover + digital twin for future works

This ensures absolute clarity from the first scan to the final signed-off drawing.

Benefits for Australian Projects

✔ Parts fit first time

✔ Shutdown durations reduced

✔ Fabricators receive complete, accurate information

✔ Safer site access with fewer high-risk activities

✔ Eliminates rework, delays, and measurement errors

✔ Enhances engineering collaboration

✔ Reduces total project cost

LiDAR scanning isn’t just a measurement method — it’s a competitive advantage.

Why Choose Hamilton By Design

  • Over a decade of experience in heavy industry
  • Extensive CHPP and mining plant expertise
  • SolidWorks Simulation, FEA, and advanced modelling capability
  • Fast mobilisation across Australia
  • Detailed, fabrication-ready deliverables
  • LinkedIn-trusted and industry-proven
  • Engineering accuracy at every step

For clients across the Hunter Valley, Bowen Basin, Pilbara, NSW, QLD, WA, and SA — we offer scalable, high-precision digital engineering that delivers reliability and confidence.

Hamilton By Design logo displayed on a blue tilted rectangle with a grey gradient background

Ready to Start Your Project?

Hamilton By Design offers 3D LiDAR scanning anywhere in Australia, from mine sites to manufacturing plants to data centres.

If you’re planning:

  • an upgrade
  • a shutdown
  • a brownfield expansion
  • a feasibility study
  • or an equipment replacement

…LiDAR scanning is the smartest starting point.

Contact us today to book a site scan or request a proposal.

Name
You would like to:

3D Point Clouds Are a Game-Changer for Your Projects

Your Experts in 3D Laser Scanning & Mechanical Design

3D CAD Modelling | 3D Scanning

3D Experience Platform Login

Posted on

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.

Hamilton By Design logo displayed on a blue tilted rectangle with a grey gradient background

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

Name
You would like to: