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Mechanical Design

Mechanical Design & Custom Equipment Layouts

Consulting-led mechanical engineering for real-world plants and equipment

At Hamilton By Design, we help owners, operators and project teams turn practical ideas into safe, buildable and reliable mechanical solutions.

Whether you’re upgrading a brownfield plant, resolving a persistent reliability issue or planning a new process line, we provide consulting-led mechanical design and custom equipment layouts that are grounded in real site conditions and fabrication reality.

How we help

We work as an extension of your project or maintenance team to:

  • Define the problem clearly – capacity, reliability, safety, access, compliance or all of the above
  • Capture the real geometry – using drawings, site measurements and (where required) 3D LiDAR scanning
  • Develop mechanical concepts – multiple options, with pros/cons and constructability in mind
  • Engineer the details – materials, load paths, supports, fixings, wear protection, sealing and maintainability
  • Produce fabrication-ready information – so your fabricator and installers know exactly what to build and how it fits

We stay involved from concept through to installation support, so there’s one accountable engineering contact from start to finish.

What we design

Our team can assist with both discrete equipment and integrated plant layouts, including:

  • Chutes, hoppers & bins – new designs, flow improvements, wear-liner upgrades, debottlenecking
  • Conveyors & transfer stations – stringer and gantry layouts, transfer interfaces, guarding and access
  • Pump, pipework & slurry systems – skids, manifolds, spool arrangements, supports and maintenance access
  • Tanks, vessels & sumps – mechanical layout, nozzles, platforms, wear and corrosion allowances
  • Screens, crushers & feeders interfaces – infeed/outfeed modifications, support framing and maintenance envelopes
  • Maintenance access & safety systems – platforms, ladders, stairs, handrails, lifting points and handling solutions
  • General plant layouts – equipment positioning, clearances, access routes and tie-ins to existing plant

If it bolts down, rotates, carries load or moves material, we can help engineer it.

Our design approach

We treat every engagement as a consulting assignment, not just a drafting task. A typical workflow:

  1. Clarify objectives & constraints
    • Performance and throughput targets
    • Site standards, client specifications and applicable Australian Standards
    • Shutdown windows, installation constraints and budget
  2. Capture the existing situation
    • Review existing drawings and vendor data
    • Undertake site inspections
    • Apply 3D LiDAR scanning where high accuracy or complex interfaces are critical
  3. Concept development
    • Generate alternative concepts with different risk, cost and complexity profiles
    • Workshop options with your team to incorporate operator and maintainer input
    • Shortlist a preferred concept for detailed design
  4. Mechanical design & detailing
    • 3D modelling of equipment and layouts in SolidWorks
    • Connection details, wear areas, load paths and serviceability resolved
    • Integration with structures, civils and adjacent plant
  5. Verification & review
    • Hand calculations and/or FEA where appropriate for critical components
    • Formal design reviews with stakeholders and fabricators
    • Buildability, transport and lifting checks
  6. Documentation for fabrication & installation
    • Fabrication drawings, BOMs and cutting lists
    • GA drawings and layout plans
    • Installation notes and mark-ups for site teams

Typical deliverables

When you engage Hamilton By Design for mechanical design and custom equipment layouts, you can expect:

  • 3D models of equipment and plant layouts
  • Fabrication drawings and detail drawings suitable for workshop use
  • General arrangement drawings with clear dimensions and interfaces
  • Bill of materials and component lists
  • Marked-up layout plans and sections for installers and other disciplines
  • Supporting calculation packs and technical notes (where required)

Where this service adds value

Our mechanical design & layout services are particularly valuable for:

  • Brownfield upgrades & debottlenecking
    • Fitting new equipment into congested plants
    • Resolving recurring blockages, spillage or wear issues
  • Shutdown-driven projects
    • Designing with install sequences and crane/lifting limits in mind
    • Reducing surprises on the shutdown critical path
  • New process lines & plant extensions
    • Co-ordinating mechanical, structural and access requirements early
    • Avoiding late design clashes and rework
  • Safety & compliance improvements
    • Guarding, access and maintenance improvements
    • Bringing legacy equipment up to current standards

Why work with Hamilton By Design?

  • Engineer-led, not drafter-led – Your layouts are driven by mechanical engineers with hands-on plant experience.
  • Single-source accountability – From site capture to 3D model to fabrication drawings, you deal with one team.
  • Brownfield specialists – Comfortable working around existing constraints, legacy drawings and incomplete data.
  • Fabrication-friendly outputs – We understand workshops and installers; our drawings are prepared with them in mind.
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Ready to talk about your next mechanical design or layout change?

Whether you have an early idea, a recurring problem or a confirmed shutdown coming up, we can help you scope, design and document a solution that fits your site and your budget.

Get in touch with Hamilton By Design to discuss your mechanical design & custom equipment layout needs, or explore our other service pages for:

  • 3D CAD Modelling & Mechanical Drafting
  • 3D LiDAR Scanning for As-Built & Brownfield Engineering
  • Finite Element Analysis (FEA) & Mechanical/Structural Assessment
  • Industrial Machinery & Plant Systems Design
  • SolidWorks Sustainability Tools — Environmental Impact & Material Optimisation

We’re here to help you move from concept to constructible, with confidence.

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Mechanical Plant Optimisation

Mechanical Plant Optimisation: Boosting Throughput, Reliability and Safety Across Australia

Industrial plants are under more pressure than ever to deliver higher output, reduce downtime and operate safely. Ageing equipment, inconsistent maintenance, and brownfield constraints often limit performance — but with the right engineering approach, even long-running plants can achieve major efficiency gains.

At Hamilton By Design, we specialise in mechanical plant optimisation using a powerful combination of engineering expertise, high-accuracy LiDAR scanning, precise 3D modelling, and practical redesign strategies that deliver measurable improvements.

If your goal is higher throughput, fewer breakdowns and safer shutdowns, this guide explains how mechanical optimisation transforms plant performance.

Why Mechanical Plant Optimisation Is Essential

Most processing plants — from CHPPs and quarries to manufacturing and power stations — suffer from the same long-term issues:

  • Reduced throughput
  • Conveyor misalignment
  • Flow bottlenecks in chutes and transfer points
  • Vibration, cracking and structural fatigue
  • Outdated drawings and unknown modifications
  • Premature wear and high maintenance costs
  • Shutdown overruns due to poor fit-up

Optimisation tackles these issues using real engineering data, not assumptions.

Step 1: LiDAR Scanning to Capture True As-Built Conditions

As equipment ages, it moves, twists and wears in ways that drawings rarely capture. Our FARO laser scanners map a complete digital twin of your plant with ±1–2 mm accuracy, giving engineers:

  • Full geometry of structural frames
  • Wear patterns inside chutes
  • Deflection in platforms, conveyor trusses and supports
  • Misalignment in pipes, pulleys and mechanical drives
  • Clash risks for future upgrades

This becomes the foundation of all optimisation work — ensuring upgrades fit first time.

Step 2: 3D Modelling & Engineering Redesign

Hamilton By Design converts point-cloud data into SolidWorks models to identify optimisation opportunities such as:

  • Reprofiling chutes for smoother flow
  • Strengthening or realigning structural members
  • Repositioning pumps or motors
  • Correcting conveyor and drive alignment
  • Redesigning access platforms for maintenance
  • Improving liner selection and service life

Every model is fabrication-ready, eliminating costly rework during shutdowns.

Step 3: Material Flow & Conveyor Performance Improvement

Flow constraints are one of the biggest sources of lost production. Through engineering review, modelling and experience, we address:

  • Impact zones causing excessive wear
  • Restrictive chute geometry
  • Poorly performing transfer points
  • Belt-tracking issues
  • Flow blockages
  • Inefficient material transitions

These improvements often deliver immediate gains in throughput and reliability.

Step 4: Mechanical Integrity & Reliability Assessments

We also perform condition assessments to understand the root causes of downtime:

  • Vibration analysis
  • Cracking and corrosion detection
  • Bearing, gearbox and pulley assessment
  • Thermal/overload risks
  • Misalignment and load distribution issues

This supports predictive maintenance and informed upgrade planning.

Step 5: Shutdown Planning & Upgrade Execution

By combining scanning, modelling and mechanical design, we ensure that every upgrade:

  • Fits perfectly into existing brownfield spaces
  • Reduces time on tools
  • Eliminates site modifications
  • Improves safety during installation
  • Delivers predictable shutdown timelines

Clients commonly see ROI within the first shutdown cycle.

Benefits of Mechanical Plant Optimisation

When optimisation is done properly, plants experience:

✔ Measurable throughput increases

✔ Longer equipment life

✔ Reduced wear and maintenance costs

✔ Safer operation and shutdown execution

✔ Accurate documentation for future projects

✔ Extended reliability of mechanical systems

With the right engineering support, even ageing plants can operate like new.

Serving Clients Across Australia

Hamilton By Design supports mechanical plant optimisation projects across:
Sydney, Newcastle, Hunter Valley, Central Coast, Bowen Basin, Surat Basin, Pilbara, Perth, Adelaide, Melbourne and regional Australia.

We work across mining, CHPPs, quarries, ports, power stations, manufacturing and heavy industrial sites.

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Ready to Optimise Your Plant?

If you want higher throughput, better reliability and safer operation, mechanical plant optimisation is the smartest investment you can make.

Or reach out directly for a project discussion.

Hamilton By Design — Engineering Certainty for Complex Plants.

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SolidWorks Design Services

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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.

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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.

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3D Laser Scanning for Engineering

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3D Laser Scanning for Engineering

At Hamilton By Design, we deliver high-accuracy 3D laser scanning tailored specifically for engineering projects across mining, heavy industry, manufacturing, buildings and infrastructure.

Whether you’re planning a shutdown upgrade, solving a site fit-up problem or updating critical as-built documentation, our engineering-grade scans give your team the confidence to design, fabricate and install with millimetre-level accuracy.

Choosing the Right Scanner for the Right Engineering Discipline

One of the most overlooked aspects of 3D laser scanning is scanner selection.
Different scanners are designed for different forms of engineering work:

  • Civil works / road works scanners prioritise coverage and speed
  • Structural engineering scanners require higher accuracy across steelwork and vertical alignment
  • Mechanical engineering demands the highest level of precision for equipment tie-ins, rotating machinery, platework and interfaces

While some overlap exists between these disciplines, a single scanner cannot deliver optimal accuracy across all engineering environments. Using one device for civil, structural and mechanical scopes inevitably leads to accuracy losses, which then flow into the design, fabrication and installation phases.

At Hamilton By Design, we select the scanner and workflow that best matches your engineering discipline, ensuring the data you receive aligns with the tolerances required for your project—not just a “one-size-fits-all” output.

Why 3D Laser Scanning for Engineering Projects?

Traditional tape-measure surveys and hand sketches simply can’t keep up with the complexity of modern plants and structures.

3D laser scanning for engineering replaces guesswork with precise digital data:

  • Capture true as-built conditions – including twists, deflections, corrosion losses and historic modifications
  • Eliminate rework and site clashes – check new designs against the point cloud before fabrication
  • Speed up shutdowns – reduce on-site measuring time and keep personnel out of hazardous areas
  • Create a single source of truth – supporting design, maintenance, safety and future expansion

Our 3D Laser Scanning Services

We provide end-to-end scanning solutions, from on-site data capture through to fabrication-ready models and documentation.

1. On-Site 3D Laser Scanning

  • High-accuracy terrestrial 3D LiDAR scanners matched to engineering discipline
  • Safe data capture in operational plants and confined access locations
  • Registration aligned to site grid, survey control or local benchmarks
  • Colourised or greyscale point clouds depending on scope needs

2. Engineering-Grade 3D Modelling

Using the scan data, we develop high-fidelity models in SolidWorks and other CAD platforms:

  • Structural steel, access systems and platforms
  • Chutes, hoppers, vessels, tanks and ductwork
  • Conveyors, transfer stations and materials handling systems
  • Mechanical equipment envelopes, mounting points and tie-ins
  • Building interiors, architectural features and services layouts

3. As-Built Documentation & Drawings

We produce clear, fabrication-ready documentation, including:

  • As-built GA drawings and layout packages
  • Detailed fabrication drawings and BOMs
  • Connection and interface detailing
  • Clearance envelopes and clash-review drawings for shutdown planning

4. Digital Quality Assurance

Our scanning workflows verify installation accuracy and compliance:

  • Compare new steelwork or equipment against the design model
  • Check critical dimensions pre- and post-shutdown
  • Provide QA evidence for clients, regulators and insurers

Industries We Support

Our engineering scanning services support:

  • Mining & CHPPs – draglines, bucket-wheel reclaimers, conveyors, chutes, screen decks, process plant steelwork
  • Power stations & energy – boilers, turbine halls, pipe racks, coal handling and ash systems
  • Heavy manufacturing – workshops, cranes, production lines, process equipment
  • Buildings & infrastructure – plant rooms, services, heritage structures, refurbishment projects
  • Data centres & critical facilities – equipment layouts, cable pathways, HVAC and expansion planning

If your project demands tight interfaces, shutdown precision or difficult-to-measure geometry, 3D laser scanning provides immediate value.

Our Typical Workflow

1. Scope & Planning

We meet with engineers, supervisors and project managers to define accuracy requirements, scanning areas and deliverables.

2. On-Site Scanning

We mobilise to site, complete inductions and capture the plant with minimal disruption.

3. Registration & QA

Scans are unified into a verified point cloud referenced to known control.

4. 3D Modelling & Design Support

We create engineering-grade models that integrate seamlessly into your CAD workflow.

5. Deliverables & Review

Point clouds, models and drawings are provided in your requested formats, with remote or in-person review.

6. Ongoing Support

Need to add new platforms, chutes or modifications later? We can extend the model and reuse existing scan data.

Benefits for Engineering Teams

Partnering with Hamilton By Design delivers:

  • Reduced shutdown risk – fewer installation surprises
  • Better design decisions – engineers see the actual plant, not outdated drawings
  • Shorter site time – thousands of measurements captured in hours
  • Improved safety – less exposure to heights, confined spaces and live equipment
  • Clear communication – 3D visualisations improve stakeholder understanding

Accuracy, Equipment & Data Formats

We use engineering-grade LiDAR scanners capable of millimetre-level accuracy at typical working distances—selected specifically to match your engineering discipline.

Typical deliverables include:

  • Registered point clouds (E57, RCP/RCS, LAS)
  • SolidWorks and STEP models
  • 2D DWG/DXF drawings
  • PDF QA reports and review packs
  • Navisworks-ready models for clash detection

We tailor outputs to fit your preferred software environment.

Why Work with Hamilton By Design?

  • Mechanical and structural engineering expertise – we scan with design intent in mind
  • Extensive heavy-industry background – mining, CHPPs, power and processing plants
  • Complete end-to-end capability – scanning, modelling, engineering and drawings
  • Australia-wide service – Central Coast, Hunter Valley, Newcastle, Bowen Basin, Surat Basin, Pilbara, Perth, Adelaide, Sydney and more

When you combine accurate data with real-world engineering experience, you get designs that are safe, buildable and cost-effective.

Ready to Talk About Your Next Project?

If you’re planning a shutdown, upgrade or complex retrofit, now is the perfect time to integrate 3D laser scanning for engineering into your workflow.

📞 Call:
📧 Email:
🌐 Website: www.hamiltonbydesign.com.au

We’re ready to review your scope, assess your drawings and help you de-risk your next project.

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Ready to Talk About Your Next Project?

If you’re planning a shutdown, upgrade or complex retrofit, now is the perfect time to integrate 3D laser scanning for engineering into your workflow.

We’re happy to review your scope, look over existing drawings and recommend how scanning and 3D modelling can de-risk your next project.

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SolidWorks FEA Simulation

SolidWorks FEA Simulation

At Hamilton By Design, we use SolidWorks Simulation FEA to help mining, manufacturing, power generation and industrial clients make better decisions before anything is cut, welded or installed.

Whether you’re upgrading a chute, checking a pressure vessel, or validating a complex brownfield retrofit, our team can simulate real-world loads, temperatures and constraints so you know how your design will behave in service.

Why use SolidWorks FEA with Hamilton By Design?

  • Mechanical engineers with real site experience – CHPPs, conveyors, reclaimers, pressure vessels, structures and plant equipment.
  • Seamless link to 3D CAD – we model in SolidWorks, analyse in SolidWorks Simulation, then deliver fabrication-ready drawings.
  • Engineering-grade results – correct boundary conditions, meshing control and code-aligned assessment where required.
  • Clear reports for decision-makers – not just stress plots, but explanations, factors of safety and practical recommendations.

Our SolidWorks FEA Capabilities

We offer a broad range of analysis types, from straightforward linear static checks through to advanced contact, thermal and fatigue studies.

1. Linear Static & Structural Integrity

For components and assemblies under static loading:

  • Linear Static (parts and assemblies)
  • Linear Static – multi-body assemblies
  • Beam and Shell element models for frames, platforms, platework and tanks
  • Static Stress (parts)
  • Static Stress (assemblies)
  • Contacts and contact sets (bonded, no-penetration, friction etc.)
  • Large displacement behaviour for flexible or slender structures

Typical use cases:

  • Platforms, walkways, supports, frames
  • Brackets, bases, machine frames and guarding
  • Brownfield modifications and tie-ins

2. Modal, Frequency & Buckling Analysis

Understanding how structures respond to vibration and instability:

  • Frequency / Modal analysis
  • Modal / Frequency analysis (eigenfrequencies and mode shapes)
  • Buckling Analysis (eigenvalue / linear buckling)
  • Modal / Buckling studies for slender structures

Typical use cases:

  • Avoiding resonance in platforms, ducts, chutes and pipework
  • Screening structures against equipment running speeds
  • Checking risk of buckling under compressive loads

3. Thermal Analysis (Steady & Transient)

Thermal loading can be just as critical as mechanical loading. We perform:

  • Steady State Thermal analysis
  • Transient Thermal analysis
  • Coupled thermal–stress workflows (temperature → stress)

Typical use cases:

  • Hot chutes, ducts, kilns and enclosures
  • Equipment in high-temperature environments
  • Evaluating thermal gradients prior to stress assessment

4. Fatigue & Life Estimation

Assessing how long components are likely to last under cyclic loading:

  • Fatigue analysis using Stress-Life (SN curves)
  • Fatigue Analysis / Fatigue (SN Curves)
  • Fatigue – Stress-Life (SN curves) for variable loading conditions

Typical use cases:

  • High-cycle fatigue in vibrating plant and supports
  • Welded details on chutes, frames and platforms
  • Repeated loading on mechanical components

5. Drop Test & Impact-Type Events

Where equipment may be dropped, impacted or experience short-duration loads:

  • Drop Test simulations (rigid and flexible bodies)
  • Drop Test (explicit-like method within SolidWorks Simulation)

Typical use cases:

  • Handling frames, lifting devices, skids
  • Enclosures, housings and protective covers
  • Equipment subject to accidental drop or impact

6. Pressure Vessel & Stress Linearisation

We support pressure vessels and pressurised equipment with:

  • Pressure Vessel evaluation
  • Pressure Vessel / Stress Linearization for membrane and bending stress extraction
  • Assessment against design criteria (in conjunction with relevant codes/standards as required)

Typical use cases:

  • Tanks, vessels, pipework branches and nozzles
  • Pressure retaining components in process plants

7. Topology Optimisation & Design Refinement

For weight reduction and concept development:

  • Topology Optimisation for parts and sub-assemblies
  • Using optimisation results to drive manufacturable designs in SolidWorks

Typical use cases:

  • Lightweight brackets and frames
  • Concept development where weight, stiffness or cost must be balanced

8. Motion & Load Extraction

Understanding motion and using it to drive realistic FEA loads:

  • Time-based Motion studies
  • Load extraction from motion into FEA (reaction forces, accelerations, etc.)

Typical use cases:

  • Mechanisms with moving arms, linkages or tooling
  • Equipment where dynamic loads dominate over static loads

9. Advanced Contacts, Meshing & Convergence

Robust results rely on correct discretisation and contact definition. We provide:

  • Advanced Contacts (nonlinear contact behaviour, friction, separation)
  • Advanced meshing strategies for complex geometry
  • Local mesh refinement around welds, holes, notches and stress raisers
  • Mesh convergence checks for confidence in results

Reporting & Engineering Documentation

Every simulation is backed by clear, traceable documentation, including:

  • Description of the model, loads, boundary conditions and assumptions
  • Material properties and factors of safety used
  • Key plots: stress, displacement, factor of safety, temperature, modes, buckling shapes etc.
  • Fatigue life estimates where applicable
  • Mesh screenshots and convergence discussion
  • Practical engineering recommendations (e.g. increase plate thickness, add stiffeners, adjust weld details).

These reports can be issued in PDF format for internal review, client submissions or integration into your broader design dossier.

How We Work With You

  1. Define the problem – loads, constraints, operating conditions and success criteria.
  2. Build or import the CAD model – we model in SolidWorks or clean up your existing geometry.
  3. Set up the study – select the appropriate FEA type, materials, contacts and mesh.
  4. Run and refine – iterate as needed to achieve stable, converged results.
  5. Recommend improvements – we help you interpret the results and adjust the design.
  6. Deliver documentation – final models, plots and reports ready for approval or fabrication.

Discuss Your Next SolidWorks FEA Project

If you need confidence that your design will perform as intended – whether it’s a small bracket or a critical plant upgrade – our team can help.

Hamilton By Design combines SolidWorks FEA simulation with practical engineering and fabrication understanding to de-risk projects across mining, heavy industry, power generation and manufacturing.

Get in touch to discuss your next project, share a model, or explore whether FEA can help you solve a specific problem before it becomes a shutdown headache.

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SolidWorks

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SolidWorks Modelling, Drafting & Engineering Services

Precision CAD for Mining, Manufacturing, Construction & Industrial Projects Across Australia

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SolidWorks is at the heart of modern engineering design — and at Hamilton By Design, it forms the foundation of our entire digital engineering workflow. We use SolidWorks to transform field data, LiDAR scans, sketches and engineering intent into accurate, fabrication-ready models and drawings that fit first time on site.

From mining wash plants and conveyors to custom machinery, structural steel and plant upgrades, our SolidWorks capability supports projects across heavy industry, manufacturing, power stations and construction sectors throughout Australia.

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Why SolidWorks?

SolidWorks is one of the world’s leading parametric 3D CAD platforms. It allows designers, drafters, engineers and fabricators to work collaboratively inside a powerful modelling environment that supports precision, automation and engineering validation.

Using SolidWorks, we can deliver:

  • Fully parametric 3D models
  • Intelligent assemblies with clear structure
  • Accurate fabrication, machining and general arrangement drawings
  • DXFs for laser/plasma cutting
  • BOMs and part numbering systems
  • Clash checking and motion studies
  • Engineering simulation (FEA) when required

Whether you’re designing new equipment or upgrading existing infrastructure, SolidWorks ensures accuracy, repeatability and seamless integration with real-world fabrication workflows.

Our SolidWorks Services

Hamilton By Design offers a complete suite of SolidWorks engineering and drafting services, including:

3D Parametric Modelling

  • Mechanical components and assemblies
  • Structural steel frames, walkways and supports
  • Chutes, tanks, hoppers, piping and mechanical equipment
  • Models built from LiDAR point clouds, sketches or legacy drawings
  • Configurable models for product variations

2D Drafting & Detailed Drawing Production

  • Fabrication drawings with weld symbols, material specs and tolerances
  • Machining drawings with hole tables, GD&T and section details
  • Assembly drawings with exploded views and Bills of Materials
  • General arrangement (GA) drawings for installation and site coordination

As-Built Modelling & Revision Updates

  • Laser scan–based as-built modelling for accuracy within ±1–3 mm
  • Updating outdated or incomplete drawing sets
  • Reverse-engineering legacy equipment and parts
  • Incorporating site mark-ups and supervisor feedback

Design for Manufacture & Installation (DFM/DFI)

  • Models and drawings structured around efficient workshop fabrication
  • Logical transport splits and lifting points (as directed by engineers)
  • Identifying potential installation conflicts before fabrication
  • Seamless coordination with boilermakers, machinists and installers

Simulation & Engineering Validation (FEA)

When required for engineering refinement, we can integrate:

  • Static FEA
  • Weld analysis
  • Deflection studies
  • Bolt and connection checks
  • Material optimisation

Industries We Support With SolidWorks

Our SolidWorks services support clients across:

  • Coal wash plants (CHPP), mining and materials handling
  • Hard rock processing plants
  • Steel fabrication and manufacturing
  • Power stations and energy infrastructure
  • Industrial construction and commercial buildings
  • Data centres and modular upgrades
  • Mechanical equipment design, jigs and fixtures

If it’s made, machined, fabricated or installed — SolidWorks helps bring it to life.

  • SolidWorks Simulation von Mises stress plot of an internally pressurised pressure vessel, viewed from above, showing colour-mapped stress distribution from low (blue) to high (red) with pressure arrows applied to the internal surfaces and deformation exaggerated for visualisation

SolidWorks + 3D Laser Scanning = Engineering-Grade Accuracy

One of Hamilton By Design’s strongest capabilities is combining SolidWorks with high-accuracy LiDAR scanning.
This workflow ensures that every model and drawing is aligned with true site conditions — drastically reducing rework, clashes and shutdown costs.

Our workflow:

  1. LiDAR Scan → Point cloud capture
  2. Registration & Cleanup → Precise as-built data
  3. SolidWorks Modelling → Fit-for-purpose geometry built to site reality
  4. FAB Drawings → Ready for plasma cutting, machining and workshop fabrication
  5. Installation Confidence → Fit-first-time outcomes

This workflow is ideal for brownfield upgrades, shutdown preparation, chute replacements, platforms and mechanical modifications.

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Why Choose Hamilton By Design for SolidWorks Work?

We bring the perfect blend of engineering experience, drafting expertise and practical understanding of industrial environments.

You benefit from:

  • Deep experience in mining, industrial and fabrication projects
  • Models and drawings that are clean, organised and easy for your team to work with
  • A site-aware mindset — considering lifting, access, installation and maintenance
  • Fast turnaround when deadlines, shutdowns and fabrication schedules matter
  • Flexible engagement — project-by-project, hourly or ongoing drafting support
  • Direct communication with a mechanical engineer, not just a CAD operator

Our aim is not just to draw — but to partner with you to deliver better engineering outcomes.

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Engage SolidWorks Specialists Today

Whether you need additional drafting support, a full engineering drawing package, or a complete as-built model from a laser scan, Hamilton By Design can help.

Let’s discuss your project requirements
We’ll tailor a SolidWorks package that matches your scope, timeline and fabrication needs.

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