Category: Smelting

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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.

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The Future of Smelting & Steelmaking:

Trends Shaping a Greener, Smarter Industry

Steel has been the backbone of industrial progress for over 150 years. It is the invisible framework behind our skyscrapers, bridges, transport systems, and modern cities. But the industry that gave us the Industrial Revolution is now facing one of the greatest transitions in its history. The combined pressures of climate change, regulatory scrutiny, fluctuating energy costs, and global trade realignments are forcing steelmakers to rethink how steel is made, used, and traded.

Recent news reports show a fascinating picture: a sector in the middle of transformation, experimenting with new technologies like hydrogen-based direct reduction, while still relying on traditional blast furnace smelting to meet soaring demand. In this article, we explore the future direction of the smelting and steelmaking industry, what challenges lie ahead, and where the biggest opportunities are likely to emerge.

The Push for Green Steel

Hydrogen & Direct Reduced Iron (DRI): A Pathway to Decarbonization

Hydrogen-based steel production remains the single most promising pathway for deep decarbonization in the steel sector. Instead of using metallurgical coal and coke to chemically reduce iron ore, hydrogen can be used to produce direct reduced iron (DRI) that can then be melted in an electric arc furnace (EAF). This dramatically cuts CO₂ emissions, especially if the hydrogen is produced using renewable energy.

Projects like Salzgitter’s Salcos program in Germany are leading the way. Salzgitter has been developing one of the most ambitious hydrogen-based steel transformation roadmaps in Europe, gradually phasing in hydrogen reduction units and retiring carbon-intensive blast furnaces. Similarly, Australia’s NeoSmelt initiative, backed by Rio Tinto and ARENA, is exploring a combination of DRI and electric smelting furnaces to create a pathway that works for Australian ore quality and energy markets.

But this transition is anything but smooth. Salzgitter has recently delayed later stages of its program, citing economic and regulatory headwinds, such as the high cost of hydrogen, uncertain carbon pricing, and the slow rollout of renewable energy infrastructure. This highlights a hard truth: the green transition will not be instant or cheap. The next decade will likely be defined by pilot projects, incremental scale-ups, and careful balancing between economic viability and climate commitments.

The Coal Paradox

Even as green steel makes headlines, metallurgical coal is seeing a surprising resurgence. Demand for coal-based blast furnace production remains robust, especially in China and India, where domestic infrastructure spending continues to grow. In fact, recent research from the Global Energy Monitor shows that coal-based capacity is still expanding, even as global climate targets call for steep reductions in emissions.

This paradox points to the transitional nature of the current era. For the foreseeable future, the world will be living in a dual-track steel economy: one track relying on traditional blast furnaces and coke ovens to meet near-term demand, and another experimenting with hydrogen, electric smelting, and alternative reduction technologies.

For businesses, this means they cannot simply abandon existing capacity overnight. Instead, expect to see retrofit investments to improve the efficiency of blast furnaces, capture more waste heat, and install carbon capture and storage (CCS) where feasible. This “cleaner coal” approach will act as a bridge until low-carbon technologies can compete at scale on cost and availability.

Regional Shifts & Strategic Investments

Australia’s Green Steel Ambitions

Australia is emerging as a key player in the global conversation on sustainable steelmaking. The country has vast high-grade iron ore resources, growing renewable energy capacity, and a strategic interest in maintaining domestic steelmaking capability.

  • BlueScope’s $1.15B blast furnace reline at Port Kembla is one of the largest industrial projects in the nation’s history, designed to keep steel production secure for another 20 years. This investment shows that Australia is taking a pragmatic approach — continuing to support blast furnace technology while planning for a green future.
  • The NeoSmelt project, which just secured nearly $20M in government funding, is a potential game-changer. It will explore how to combine renewable-powered hydrogen and electric furnaces to make a commercial-scale green steel process that works with Australian ore.
  • The potential takeover of Whyalla Steelworks by a consortium led by BlueScope could turn the plant into a testbed for low-emissions ironmaking, providing a national blueprint for decarbonizing heavy industry.

Global Trade & Policy Realignment

Meanwhile, trade policy is also shaping the future. The EU and U.S. have resumed talks to revisit steel and aluminium tariffs, with a focus on creating carbon-based trade measures. If implemented, this could reward producers who adopt low-carbon technologies while penalizing those that rely on high-emission processes. For global producers, this will accelerate investment in low-emissions capacity to stay competitive in export markets.

Innovation Beyond Furnaces

The transformation of steelmaking is not just about switching fuels — it’s about reimagining the entire production system.

  • Modular, low-emission smelting plants like those being developed in Western Australia by Metal Logic allow companies to build capacity closer to demand centers, reduce transport emissions, and scale production up or down as needed.
  • Digital twins and AI-driven process control are making smelting more efficient. By modeling every step of the steelmaking process, producers can optimize energy use, reduce material losses, and increase yield — all of which improve profitability and lower emissions simultaneously.
  • Circular economy practices, such as increased use of scrap steel in EAFs, are becoming a central strategy. Recycling steel uses a fraction of the energy required to make virgin steel and fits neatly into the industry’s sustainability narrative.

This convergence of physical and digital innovation will likely create a new generation of steel plants that are smaller, smarter, and cleaner than their 20th-century predecessors.

Where the Industry is Headed

Looking ahead, the future of smelting and steelmaking will be defined by hybridization, regulation, and resilience:

  • Hybrid production systems will dominate for at least the next decade. Expect blast furnaces to operate alongside hydrogen-based DRI units and electric smelters as companies transition gradually.
  • Stricter carbon regulations will push companies to adopt low-carbon pathways faster than market forces alone would dictate. Carbon border adjustment mechanisms (CBAMs) will effectively tax “dirty steel” in major economies, making investment in green capacity a competitive necessity.
  • Domestic capability building will remain critical. The COVID-era supply chain crises reminded governments why domestic production matters. Expect to see policies that support keeping steelmaking onshore, even if that requires subsidies or preferential procurement.
  • Collaborative innovation will become the norm. Mining giants, energy producers, and technology firms are already forming alliances to solve the “green steel puzzle.” This cross-industry collaboration will unlock new efficiencies and accelerate commercialization.

Final Thoughts

The smelting and steelmaking industry is standing at the crossroads of history. The coming years will test its ability to balance sustainability with profitability, scale with flexibility, and tradition with innovation.

Companies that embrace this challenge — investing in low-carbon technology, digital transformation, and strategic partnerships — will not just survive the coming disruption but thrive as leaders in a new, greener industrial age. Steel may be one of the oldest materials in human civilization, but its future is being forged right now, and it has never been more exciting.

References

Salzgitter Salcos Project

Global Energy Monitor – Steel Sector Reports

ARENA NeoSmelt Funding Announcement

Challenges in the Australian Smelting Industry

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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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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

  1. Preparation & Planning

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

  2. Data Capture

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

  3. Processing & Registration

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

  4. Post-processing & Deliverables

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

  5. 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

#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

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3D Laser Scanning and CAD Modelling Services | Hamilton By Design

There are two things we’ve always believed at Hamilton By Design:

  1. Accuracy matters.
  2. If you can model it before you make it, do it.

That’s why when the FARO Focus S70 hit the scene in 2017, we were early to the party — not just because it was shiny and new (though it was), but because we knew it would change how we support our clients in mining, processing, and manufacturing environments.

The S70 didn’t just give us a tool — it gave us a superpower: the ability to see an entire site, down to the bolt heads and pipe supports, in full 3D before anyone picked up a wrench. Dust, heat, poor lighting — no problem. With its IP54 rating and extended temperature range, this scanner thrives where other tools tap out.

And we’ve been putting it to work ever since.

3D laser scan of mechanical plant

“Measure Twice, Cut Once” Just Got a Whole Lot More Real

Laser scanning means we no longer rely on outdated drawings, forgotten markups, or that sketch someone did on the back of a clipboard in 2004.

We’re capturing site geometry down to millimetres, mapping full plant rooms, structural steel, conveyors, tanks, ducts — you name it. And the moment we leave site, we’ve already got the data we need, registered and ready to drop into SolidWorks.

Which, by the way, we’ve been using since 2001.

Yes — long before CAD was cool, we were deep into SolidWorks building models, simulating loads, tweaking fit-ups, and designing smarter mechanical solutions for complex environments. It’s the other half of the story — scan it, then model it, all in-house, all under one roof.

Safety by Design – Literally

Here’s the part people often overlook: 3D laser scanning isn’t just about accuracy — it’s about safety.

We’ve worked across enough plants and mine sites to know that the real hazards are often the things you don’t see in a drawing. Tight access ways. Awkward pipe routing. Obstructions waiting to drop something nasty when a shutdown rolls around.

By scanning and reviewing environments virtually, we can spot those risks early — hazard identification before boots are even on the ground. We help clients:

  • Reduce time-on-site
  • Limit the number of field visits
  • Minimise exposure to high-risk zones
  • Plan safer shutdowns and installations

That’s a big win in any plant or processing facility — not just for compliance, but for peace of mind.

SolidWorks 3D Modelling CAD model from site scan

From Point Cloud to Problem Solved

Since 2017, our scanning and modelling workflows have supported:

  • Brownfield upgrade projects
  • Reverse engineering of legacy components
  • Fabrication and installation validation
  • Creation of digital twins
  • Asset audits and documentation updates

And when you pair that with 24 years of SolidWorks expertise, you get more than just a pretty point cloud — you get practical, buildable, fit-for-purpose engineering solutions backed by deep industry knowledge.

Thinking about your next project? Let’s make it smarter from the start.

We’ll scan it, model it, and engineer it as we have been doing for decades — with zero guesswork and full confidence.

📍 www.hamiltonbydesign.com.au

Mechanical Engineering | Structural Engineering

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3D Modelling 

SolidWorks 3D Modelling

 By Hamilton By Design | www.hamiltonbydesign.com.au

In the 1980s through to the early 2000s, AutoCAD ruled supreme. It revolutionised the way engineers and designers approached 2D drafting, enabling technical drawings to be created and shared with speed and precision across industries. For two decades, it set the benchmark for visual communication in engineering and construction. But that era has passed.

Today, we live and work in a three-dimensional world — not only in reality, but in design.

From 2D Drafting to Solid Modelling: The New Standard

At Hamilton By Design, we see 3D modelling not just as a tool, but as an essential evolution in how we think, design, and manufacture. The transition from 2D lines to solid geometry has reshaped the possibilities for every engineer, machinist, and fabricator.

With the widespread adoption of platforms like SolidWorks, design engineers now routinely conduct simulations, tolerance analysis, motion studies, and stress testing — all in a virtual space before a single part is made. Companies like Tesla, Ford, Eaton, Medtronic, and Johnson & Johnson have integrated 3D CAD tools into their product development cycles with great success, dramatically reducing rework, increasing precision, and accelerating innovation.

Where 2D design was once enough, now solid models drive machining, laser cutting, 3D printing, automated manufacturing, and finite element analysis (FEA) — all from a single digital source.

A Growing Ecosystem of Engineering Capability

It’s not just the software giants making waves — a global network of specialised engineering services is helping bring 3D design to life. Companies like Rishabh Engineering, Shalin Designs, CAD/CAM Services Inc., Archdraw Outsourcing, and TrueCADD provide design and modelling support to projects around the world.

At Hamilton By Design, we work with and alongside these firms — and others — to deliver scalable, intelligent 3D modelling solutions to the Australian industrial sector. From laser scanning and site capture to custom steel fabrication, we translate concepts into actionable, manufacturable designs. Our clients benefit not only from our hands-on trade knowledge but also from our investment in cutting-edge tools and engineering platforms.

So What’s Next? The Future Feels More Fluid Than Solid

With all these tools now at our fingertips — FEA simulation, LiDAR scanning, parametric modelling, cloud collaboration — the question becomes: what comes after 3D?

We’ve moved from pencil to pixel, from 2D lines to intelligent digital twins. But now the line between design and experience is beginning to blur. Augmented reality (AR), generative AI design, and real-time simulation environments suggest that the next wave may feel more fluid than solid — more organic than mechanical.

We’re already seeing early glimpses of this future:

  • Generative design tools that evolve geometry based on performance goals
  • Real-time digital twins updating with sensor data from operating plants
  • AI-driven automation that simplifies design iterations in minutes, not days

In short: the future of 3D design might not be “3D” at all in the traditional sense — it could be interactive, immersive, adaptive.

At Hamilton By Design — We’re With You Now and Into the Future

Whether you’re looking to upgrade legacy 2D drawings, implement laser-accurate reverse engineering, or develop a full-scale 3D model for simulation or manufacturing — Hamilton By Design is here to help.

We bring hands-on trade experience as fitters, machinists, and designers, and combine it with the modern toolset of a full-service mechanical engineering consultancy. We’re not just imagining the future of design — we’re building it.

Let’s design smarter. Let’s think in 3D — and beyond.

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www.hamiltonbydesign.com.au
✉️ anthony@hamiltonbydesign.com.au📞 0477 002 249By Hamilton By Design | www.hamiltonbydesign.com.au