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:

3D LiDAR Scan
Point Cloud Registration
3D CAD Modelling
Mechanical & Structural Engineering
Fabrication-Ready Drafting
Digital QA & Documentation

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

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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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10 December 20258 September 2026

Lidar Scanning & Engineering in Cairns

Where Tropical Ecosystems, Marine Industry & Industrial Precision Converge

Cairns is not just a gateway to reefs and rainforests — it’s a strategic hub for marine engineering, coastal infrastructure, environmental projects and remote-region logistics. With its proximity to the Great Barrier Reef, the Wet Tropics rainforest, a busy regional port, defence facilities and frequent heavy industrial and marine maintenance requirements, Cairns demands precision, flexibility and deep engineering expertise.

At Hamilton By Design, we understand those needs. Our offerings — 3D LiDAR laser scanning, mechanical and structural engineering, 3D modelling, and fabrication-ready drafting — are designed to meet the unique challenges of Northern Queensland. Whether it’s a marine-grade fabrication yard, a coastal infrastructure project, a remote-region logistics facility or an environmental structure upgrade — we deliver accuracy, compliance and quality from start to finish.

Why Cairns Is a Special Case for Engineering & Digital Surveying

Cairns combines tropical climate, marine exposure, rainforest-adjacent terrain, heritage sensitivity and strategic infrastructure in ways few other regional Australian cities do. Key aspects include:

Coastal and marine infrastructure needing resistance to corrosion, saltwater, tidal influence and cyclone-proofing.
Environmental and ecological constraints thanks to proximity to reef and rainforest — making accurate as-built documentation, impact assessments, and careful planning essential.
A busy port, marine services and vessel maintenance sector — requiring complex structural, mechanical and fabrication-grade precision.
Remote-area supply chains and logistics hubs serving Cape York, Torres Strait, Gulf communities and mining / remote-site projects.
Mixed infrastructure: commercial, marine, industrial, tourism-facing — often on tight schedules due to weather, seasonal demand or regulatory windows.

In short: for projects in Cairns, there’s no room for guesswork. What’s needed is digital accuracy, detailed planning and structured engineering from scanning to delivery.

3D LiDAR Laser Scanning — The Foundation for Reliable Project Delivery

Most coastal, marine or tropical-region facilities have complexities that challenge traditional surveying: uneven terrain, tide-influenced shorelines, dense vegetation, complex plant and structural geometry, and legacy infrastructure.

Our 3D LiDAR laser scanning solves these problems by capturing an exact “digital twin” of the existing environment — down to millimetre precision. That means:

accurate as-built geometry of buildings, wharfs, vessels, platforms, terrain, and utilities
precise mapping of structural steel, supports, pipework, stairs, and foundations
detailed spatial data for marine and coastal assets — including elevation, overhangs, clearances, and water-line references
baseline data for planning upgrades, maintenance, or compliance audits

For any project where precision is critical — from marine maintenance to coastal-infrastructure retrofits — LiDAR scanning provides the data foundation you can trust.

Learn more about our scanning service: 3D Laser Scanning

3D Modelling & Drafting: Turning Point-Clouds into Work-Ready Designs

Once the scan is complete, Hamilton By Design converts raw point clouds into intelligent 3D CAD models and fabrication-ready drawings. This step is critical when building or refurbishing:

marine-grade structural supports and frameworks
coastal infrastructure (jetties, boat ramps, wharf extensions)
buildings, sheds, warehouses with corrosion-resistant materials
processing facilities for marine, aquaculture or remote-region supply
environmental or utility infrastructure sensitive to terrain and waterline

We provide:

accurate mechanical and structural models
general-arrangement (GA) drawings
detailed fabrication drawings, isometrics, BOMs
interference / clash detection before any welding or cutting begins
digital documentation for regulatory compliance, QA and future maintenance

With this workflow, you get clean, precise, build-ready plans — essential for tropical marine environments where mistakes are expensive.

Engineering Services for Cairns’ Unique Industrial & Marine Needs

From marine maintenance to coastal infrastructure, Cairns projects often involve corrosion resistance, flooding, cyclone-proofing, load-bearing structures, and complex geometry. Hamilton By Design offers:

structural design for coastal & marine facilities (jetties, piers, decks, frames)
stress, vibration, fatigue and load capacity analysis (especially for salt-water, tidal and dynamic loads)
mechanical design for processing plants, workshops, offshore-support equipment
piping, ducting, and pressurised systems — especially in marine, water treatment or aquaculture facilities
environmental compliance support — ensuring designs accommodate tidal ranges, erosion, storm surges, vegetation and terrain

Whether for a harbour-side workshop, a marine-service shed, or remote-region logistics facility, we deliver structural integrity, regulatory compliance, and practical build plans.

Real-World Use Cases for Cairns — Where Hamilton By Design Adds Value

Marine Infrastructure & Vessel Maintenance

For shipyards, vessel refits, port-side maintenance or marine-support infrastructure, accurate spatial data + structural modelling is critical. LiDAR scanning ensures all geometry is captured — ideal for planning upgrades, retrofits or new builds with tight tolerances.

Coastal & Reef-Adjacent Infrastructure

Marine-environment facilities, boardwalks, eco-tourism builds, boat ramps, jetties or reef-support structures benefit from precise bathymetric / terrain-adjacent scans, corrosion-resistant design, and structural integrity.

Remote-Region Logistics & Utility Facilities

Supplying remote Northern Queensland or island communities often involves complex logistics, tight installation windows and harsh environmental conditions. Digital modelling + drafting supports efficient, low-risk builds and maintenance.

Industrial Workshops & Fabrication Yards

Whether for marine fabrication, equipment repair, small-scale processing, or heavy-duty maintenance — these facilities benefit from accurate as-built documentation, clash detection, and fabrication-ready drawings before work begins.

Environmentally Sensitive / Compliance Projects

Projects near rainforest or reef zones often require strict regulatory compliance, environmental impact design, storm-water management, erosion control, and terrain-aware structural planning. Our engineering services integrate these factors from the start.

Why Cairns & Hamilton By Design — The Perfect Combination

Cairns’ unique blend of tropical climate, marine exposure, environmental sensitivity, remote-region logistics and industrial demand means projects here aren’t simple. They require precision, compliance, resilience, and planning for extremes.

Hamilton By Design brings together:

3D LiDAR laser scanning for accurate as-built documentation
3D modelling & drafting to turn scan data into build-ready plans
Mechanical & structural engineering tailored to marine, coastal and tropical environments
End-to-end project documentation for compliance, QA and future maintenance

Whether you’re building a marine maintenance facility, refurbishing coastal infrastructure, servicing remote-region supply chains, or building a fabrication workshop — with Hamilton By Design, you get reliability, clarity and quality.

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LOD in BIM vs Reality Capture

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Mining Plant Upgrades

Engineering Data Governance

Australian Design Drafting Services

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9 December 20256 September 2026

Industrial Machinery Systems Design

Industrial Machinery & Plant Systems Design

Consulting-led mechanical engineering for mining, processing and manufacturing operations

Practical, engineered solutions for brownfield and greenfield industrial facilities

Hamilton By Design provides consulting-led mechanical engineering for complex industrial systems across mining, mineral processing, manufacturing and heavy industry.

We specialise in designing, upgrading and optimising machinery and plant systems that must perform reliably under real operating conditions — high loads, abrasive materials, continuous duty cycles, demanding shutdown windows and strict compliance requirements.

Whether you’re introducing new equipment, modifying existing systems or expanding production capacity, we help you move from concept to construction with clarity, accuracy and confidence.

How We Support Your Plant & Machinery Projects

Our consulting team works from the problem outward — understanding your operational objectives, constraints and shutdown timelines before we begin design.

We help clients:

Upgrade brownfield equipment while minimising downtime and rework
Design new machinery and plant systems aligned to production targets
Resolve recurring performance, wear, or reliability issues through redesign
Integrate OEM equipment into complex existing facilities
Coordinate mechanical, structural and access requirements in one model
Prepare fabrication-ready documentation that installers and workshops can rely on

Our engineering process combines real site experience, 3D CAD modelling, FEA where needed, and — for brownfield work — engineer-led 3D LiDAR scanning to ensure accuracy.

What We Design

Hamilton By Design delivers mechanical systems and plant layouts across a wide range of industrial applications:

Bulk Materials Handling Systems

Conveyors (fixed, shiftable, overland, tripper gantries)
Transfer towers and conveyor galleries
Chutes, hoppers, bins and wear lining systems
Feeders, vibratory equipment and discharge systems

Processing & Production Equipment

Screens, crushers, mills and separation equipment interfaces
Pumping systems, pipework, manifolds and slurry line transitions
Tanks, vessels, agitators and mechanical supports
Mechanical upgrades to maximise throughput or reliability

Plant Layouts & System Integration

Space-constrained brownfield layouts
New plant expansions and tie-ins
Mechanical–structural interface design
Access, maintenance and safety systems

Support Systems & Ancillary Equipment

Platforms, walkways, stairs and guarding
Maintenance stands, frames, skids and lifting/handling devices
Mobile and fixed equipment support structures

If it moves material, processes ore, mounts equipment or supports production, we can help design it.

Our Design Approach

Industrial plant design is never one-size-fits-all. Every project has operational realities, shutdown limits and site constraints. Our approach reflects that:

1. Understand the Operating Environment

We begin by understanding:

Production goals
Wear mechanisms
Availability targets
Maintenance constraints
Compliance and site standards

This ensures the design is grounded in how the plant is actually used — not how it looks on paper.

2. Capture Accurate Existing Conditions

For brownfield sites, we integrate 3D LiDAR scanning to ensure all tie-ins, clearances and interfaces match reality.
This significantly reduces rework, clashes and on-site modification.

3. Develop Practical Mechanical Concepts

We generate design options that consider:

Material flow
Access and maintenance
Installation sequence
Transport and modularisation
Cost, complexity and risk

Options are presented with pros and cons so you can decide the best path forward.

4. Engineer the Details

Using SolidWorks and analysis tools, we refine:

Load paths and structural capacity
Wear management and replaceability
Supports, fixings and serviceability
Safety, guarding, access and compliance
Liner systems and flow optimisation

5. Verify Performance & Reliability

Where appropriate, we perform:

FEA for stress, fatigue and buckling
Check calculations for structural and mechanical compliance
Flow and material behaviour assessments
Vibration or modal checks for dynamic equipment

6. Produce Fabrication & Installation Documentation

We deliver:

3D models
GA drawings
Fabrication details
BOMs and cutting lists
Installation notes
Tie-in and interface details

All documentation is prepared with fabricators, installers and shutdown teams in mind.

Where This Service Adds the Most Value

Hamilton By Design’s industrial machinery and plant system design services are ideal for:

Shutdown-driven upgrades where every hour matters
Debottlenecking and throughput improvements
Wear and reliability redesigns of problem areas
Capacity expansions requiring new equipment or system reconfiguration
Brownfield integration of OEM machines into existing plants
New plant development where early layout and mechanical decisions set project success

Why Work With Hamilton By Design?

Engineer-led design process — not drafting-first
Strong brownfield capability using 3D LiDAR for accuracy
Deep experience in mining and processing plants across Australia
Fabrication-ready deliverables developed with real workshops in mind
Clear, actionable advice grounded in practical engineering
Single-source accountability from site capture to drawings

We bridge the gap between concept and install — reducing risk, improving reliability and ensuring your plant systems actually work in the real world.

Let’s Talk About Your Next Plant or Machinery Project

Whether you’re planning a major upgrade, resolving a long-standing performance issue, or designing a new facility, our team can support you with clear, practical and engineering-driven solutions.

Contact Hamilton By Design to discuss your upcoming project, or explore our related services:

Mechanical Design & Custom Equipment Layouts
3D CAD Modelling & Mechanical Drafting
3D LiDAR Scanning for As-Built & Brownfield Engineering
FEA & Mechanical/Structural Assessment
SolidWorks Sustainability Tools & Material Optimisation

We’re ready to help you design industrial systems that perform — safely, reliably and efficiently.

Our Clients

3D LiDAR Scanning for As-Built & Brownfield Engineering

Mechanical Engineering Consulting

Manufacturing and Production

Mech Eng. Mining Industry

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Mining Plant Upgrades

Engineering Data Governance

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Mechanical Engineering Consulting

SolidWorks

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Australian Design Drafting Services

Material Handling

9 December 20258 September 2026

3D CAD Modelling & Mechanical Drafting

Engineer-led digital models and drawings that go all the way to fabrication and site

At Hamilton By Design, our 3D CAD modelling and mechanical drafting services are built for real-world engineering — not just pretty pictures.

Blue mechanical engineering icon with gear and wrench

We combine site experience, SolidWorks-based modelling and practical fabrication knowledge to produce models and drawings that installers, fabricators and maintainers can actually trust. Whether you’re upgrading a brownfield plant, designing new equipment or tidying up legacy documentation, we act as your outsourced mechanical design office, providing precise, buildable digital deliverables.

What we do as your 3D CAD & drafting consultants

We don’t just “draw what you tell us”. We work as engineering consultants across the full lifecycle of a mechanical scope:

Concept to detailed 3D models
- Parametric 3D models of mechanical equipment, plant layouts and support structures
- Options and “what-if” geometry to explore different design directions
- Early checks for fit-up, access and maintenance
Fabrication-ready mechanical drafting
- GA drawings, detail drawings and shop drawings for steelwork, chutes, hoppers, conveyors, guards and platework
- Clear dimensioning, weld symbols, notes and call-outs suitable for workshop use
- DXFs / step-files for plate nesting, profiling and CNC workflows
Brownfield & retrofit modelling
- 3D models built around existing plant geometry (often from 3D LiDAR scans)
- Retrofit equipment and modifications that are tailored to your real as-built conditions
- Clash checks and construction sequencing in tight, congested plants
BOMs and manufacturing data
- Structured Bills of Materials aligned to your procurement and ERP processes
- Cut lists, plate developments and standard part libraries
- Export to neutral formats for fabricators and OEM partners
Drawing updates & documentation clean-up
- Redrawing old 2D sketches and mark-ups into structured 3D models + 2D drawings
- Updating drawings to reflect plant modifications and shutdown works
- Creating as-built drawing sets suitable for asset registers and compliance records

How our 3D CAD process supports better mechanical outcomes

Because our modelling is led by practising mechanical engineers, every step is geared toward engineering performance, safety and constructability.

Understand the scope and constraints
We begin by clarifying duty, environment, design life, shutdown windows, lifting/install requirements and any relevant standards. This ensures the model reflects how the asset will actually be used, not just how it looks on screen.
Capture or reference the real geometry
For brownfield work, we typically integrate our 3D LiDAR scanning into the CAD workflow, so new designs are wrapped around accurate as-built geometry. For greenfield scopes, we work from P&IDs, layout drawings and vendor data.
Develop parametric 3D models
We build intelligent, parametric models in SolidWorks so changes are fast and controlled. This allows us to adjust clearances, plate thicknesses, bolt patterns and support arrangements without starting from scratch.
Review with your team early
We use 3D views, marked-up PDFs and, where useful, e-drawing viewers so your operations, maintenance and safety teams can comment before drawings are frozen. That’s where you pick up the “practical” issues — access, guarding, hoses, walkways, lifting and isolation points.
Produce fabrication and installation drawings
Once the 3D model is agreed, we generate structured 2D drawings with the right level of detail for workshop, site and client records. We can align drawing standards to your existing title blocks, revision systems and naming conventions.
Support during fabrication and construction
We remain involved as engineering consultants — answering queries from fabricators, updating drawings for site changes and supporting any design tweaks uncovered during installation or commissioning.

Where our 3D CAD & drafting services are typically used

Hamilton By Design’s 3D modelling and drafting work is focused on heavy industry, mining and manufacturing, including:

Coal handling and preparation plants (CHPPs)
Hard-rock and minerals processing plants
Conveyors, transfer stations and material handling systems
Chutes, hoppers, bins and wear-liner layouts
Pumping skids, pipework, manifolds and mechanical supports
Access platforms, walkways, handrails and maintenance structures
OEM upgrades, retrofit packages and plant debottlenecking projects

We understand the realities of shutdowns, live-plant work and remote operations. Our models and drawings are built with those constraints in mind.

Why engage Hamilton By Design as your CAD & drafting partner?

Engineer-led, not just drafting-led
All work is overseen by experienced mechanical engineers with site backgrounds, so the models and drawings naturally reflect real-world loads, clearances and maintenance needs.

Tightly integrated with 3D LiDAR scanning
For brownfield sites, we can bring in high-accuracy point clouds to minimise rework and fit-up issues. That means less cutting and welding on site, and more “first-time fit” during shutdowns.

Optimised for fabrication and installation
We think about how plates will be cut, how assemblies will be transported and lifted, and how installers will actually put things together. That mindset reduces RFIs, delays and costly rework.

Flexible engagement — from one-off drawings to full plant packages
We can help with anything from a small set of detail drawings through to complete plant layouts, equipment packages and drawing-office support across multiple projects.

Typical deliverables

When you engage Hamilton By Design for 3D CAD modelling and mechanical drafting, you can expect:

Native SolidWorks models (and other formats on request)
2D fabrication and GA drawings in PDF and DWG/DXF
Structured BOMs and part lists
Optional point-cloud and model alignment reports (for scanned sites)
Marked-up general arrangement views for use in risk assessments, HAZOPs and maintenance planning

Let’s talk about your next mechanical scope

Whether you need a single retrofit component, a new chute and transfer station, or a complete update of old mechanical drawings, Hamilton By Design can act as your external mechanical design office.

We’ll help you move from rough ideas, hand sketches and legacy drawings to accurate 3D models and fabrication-ready documentation — with engineering support built in.

Ready to discuss a project?
Get in touch to talk through your next mechanical scope, or connect this service with our related offerings in:

Mechanical Design & Custom Equipment Layouts
3D LiDAR Scanning for As-Built & Brownfield Engineering
Finite Element Analysis (FEA) & Mechanical/Structural Assessment

We’re here to help you turn complex mechanical problems into buildable, reliable solutions.

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9 December 202526 September 2026

Mechanical Design

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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:

Clarify objectives & constraints
- Performance and throughput targets
- Site standards, client specifications and applicable Australian Standards
- Shutdown windows, installation constraints and budget
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
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
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
Verification & review
- Hand calculations and/or FEA where appropriate for critical components
- Formal design reviews with stakeholders and fabricators
- Buildability, transport and lifting checks
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.

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 Engineering Consulting

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3D Reality Capture Services

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LOD in BIM vs Reality Capture

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8 December 20258 September 2026

SolidWorks 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.