From the growing commercial hubs of Parramatta and Chatswood to the complex redevelopments across Sydney’s Eastern Suburbs, the construction industry is demanding more accuracy, faster turnaround, and fewer on-site surprises.
At Hamilton By Design, we use 3D scanning and LiDAR technology to help builders, engineers, and developers capture, model, and verify real site conditions with millimetre accuracy.
Our advanced 3D models ensure every structural, mechanical, or architectural component fits perfectly on site — helping Sydney’s construction professionals deliver projects right the first time.
High-Precision Site Capture with LiDAR Scanning
Using advanced LiDAR (Light Detection and Ranging) technology, our scanners record millions of laser points per second to create a complete 3D “point cloud” of your site or structure.
Whether we’re scanning a commercial building in Chatswood, a multi-level development in Parramatta, or a heritage renovation in Sydney’s Eastern Suburbs, LiDAR scanning allows us to document every detail — without disruption to your workflow.
The result is a digital twin of your project site that forms the foundation for precise design, fabrication, and installation.
From Point Cloud to Construction-Ready Model
Once scanning is complete, our engineers convert the LiDAR data into accurate 3D CAD and BIM models that integrate seamlessly into platforms such as Revit, AutoCAD, Navisworks, and SolidWorks.
This digital workflow allows your team to:
Validate as-built conditions before design or fabrication
Identify clashes and alignment issues early
Plan site installations with confidence
Reduce rework and delays during construction
By designing and fabricating to real-world data, Sydney contractors can save valuable time and eliminate unnecessary on-site adjustments.
Why Sydney Contractors Choose 3D Scanning and LiDAR
Millimetre Accuracy: Perfect alignment between fabricated and existing structures.
Reduced Rework: Detect and fix issues before they reach site.
Improved Safety: Non-invasive scanning of hard-to-reach areas.
Faster Installation: Minimise downtime and site delays.
Better Documentation: Maintain accurate records for QA and future maintenance.
Across Chatswood, Parramatta, and Sydney’s Eastern Suburbs, our clients use LiDAR scanning to bring greater certainty to every phase of construction.
Supporting Projects Across Sydney
Hamilton By Design supports a wide range of construction and engineering projects across metropolitan Sydney, including:
Commercial and retail developments in Chatswood and Parramatta
Luxury residential projects and architectural fit-outs in Sydney’s Eastern Suburbs
Industrial and infrastructure upgrades throughout Greater Sydney
Brownfield and refurbishment projects requiring accurate as-built data
Whether it’s a new build or a complex retrofit, we make sure every part of your design fits the first time.
Partner with Hamilton By Design
If you’re managing or planning a construction project in Chatswood, Parramatta, or Sydney’s Eastern Suburbs, Hamilton By Design offers the experience and technology to capture, model, and verify your site with precision.
Our 3D scanning and LiDAR services help Sydney builders, designers, and fabricators deliver more accurate results — reducing risk, rework, and cost.
Sydney’s construction industry is booming — from commercial towers and infrastructure upgrades to industrial developments and complex refurbishments. But as sites become more congested and designs more complex, achieving perfect alignment between fabricated and installed components has never been more challenging.
That’s where 3D scanning and LiDAR technology come in. At Hamilton By Design, we provide high-precision digital capture and 3D modelling services that ensure every element of your construction project fits seamlessly together, saving time, cost, and effort onsite.
Capturing the Real Site with LiDAR Scanning
Using LiDAR (Light Detection and Ranging) scanners, we capture millions of laser measurements per second to create an exact 3D digital record — known as a point cloud — of your construction site or structure.
This means we can document existing conditions, monitor progress, and verify installations with millimetre-level precision. For Sydney builders, engineers, and contractors, that data eliminates the guesswork and drastically reduces costly clashes and rework later on.
From Point Cloud to 3D Model
Once the LiDAR data is captured, it’s processed into detailed 3D CAD and BIM models compatible with leading design software such as Revit, AutoCAD, SolidWorks, and Navisworks.
These accurate models allow design teams to:
Validate and update as-built conditions before fabrication
Detect clashes and misalignments before installation
Plan modifications and extensions with confidence
Coordinate between mechanical, structural, and architectural disciplines
By working from a true digital twin of your Sydney site, you can be sure every part — from prefabricated frames to pipe runs — will fit exactly where it should.
Why Sydney Construction Projects Are Turning to 3D Scanning
Reduced Rework: Identify design and fabrication issues before they reach site.
Improved Safety: Capture high or restricted areas without scaffolding or shutdowns.
Shorter Installation Times: Minimise downtime and delays during fit-up.
Precise Documentation: Maintain accurate records for QA and handover.
Better Collaboration: Integrate real-world data into your BIM environment.
From commercial fit-outs to infrastructure projects across Greater Sydney, 3D scanning provides a single source of truth for every stakeholder.
Typical Sydney Projects Using LiDAR and 3D Modelling
Hamilton By Design supports a range of construction and engineering clients, including:
Commercial and residential developments in the CBD and inner suburbs
Industrial plant upgrades across Western Sydney
Transport and infrastructure projects under NSW Government programs
Refurbishment and brownfield works requiring detailed as-built verification
Each project benefits from faster delivery, greater precision, and stronger communication between designers, builders, and clients.
Partner with Hamilton By Design
If you’re working on a Sydney construction or infrastructure project and need accurate 3D site data, as-built modelling, or fit-up verification, Hamilton By Design can help.
Our experienced mechanical and design specialists combine field scanning with advanced 3D modelling to deliver practical, reliable results that make construction smoother — and smarter.
In mining and mineral processing environments, small mis-fits, outdated drawings, or inaccurate assumptions can translate into shutdowns, costly rework, or worse, safety incidents. For PMs, superintendents, engineering managers and plants operating under heavy uptime and safety constraints, combining 3D scanning and 3D modelling isn’t just “nice to have” — it’s becoming essential. At Hamilton By Design, we’ve leveraged this combination to deliver greater predictability, lower cost, and improved safety across multiple projects.
What are 3D Scanning and 3D Modelling?
3D Scanning (via LiDAR, laser, terrestrial/mobile scanners): captures the existing geometry of structures, equipment, piping, chutes, supports, tanks, etc., as a dense point cloud. Creates a digital “reality capture” of the plant in its current (often messy) state.
3D Modelling: turning that data (point clouds, mesh) into clean, usable engineering-geometry — CAD models, as-built / retrofit layouts, clash-detection, wear mapping, digital twins, etc.
The power comes when you integrate the two — when the reality captured in scan form feeds directly into your modelling/design workflows rather than being a separate survey activity that’s then “interpreted” or “assumed.”
Why Combine Scanning + Modelling? Key Benefits
Here are the main advantages you get when you deploy both in an integrated workflow:
Benefit
What it Means for PMs / Engineering / Plant Ops
Examples / Impacts
Accuracy & Reality Verification
Verify what’s actually in the plant vs what drawings say. Identify deformations, misalignments, wear, obstructions, or changes that weren’t captured in paper drawings.
Scanning can be done with limited or no shutdown, and from safer vantage points. Less need for personnel to enter hazardous or confined spaces.
Scanning inside crushers, under conveyors, or at height without scaffolding.
Time & Cost Savings
Faster surveying; fewer repeat field trips; less rework; fewer surprises during shutdowns or retrofit work.
Scan once, model many; clashes found in model instead of in the field; pre-fabrication of replacement parts.
Better Shutdown / Retrofit Planning
Use accurate as-built models so new equipment fits, interferences are caught, installation time is optimized.
New pipelines routed without conflict; steelwork/supports prefabricated; shutdown windows shortened.
Maintenance & Asset Lifecycle Management
Scan history becomes a baseline for monitoring wear or deformation. Enables predictive maintenance rather than reactive.
Comparing scans over time to track wear; scheduling relining of chutes; monitoring structural integrity.
Improved Decision Making & Visualisation
Engineers, superintendents, planners can visualise the plant as it is — space constraints, access routes, clearances — before making decisions.
Clash-detection between new and existing frames; planning maintenance access; safety audits.
Digital Twin / Integration for Future-Ready Plant
Once you have accurate geometric models you can integrate with IoT, process data, simulation tools, condition monitoring etc.
Digital twins that simulate flow, energy use, wear; using scan data to feed CFD or FEA; feeding into operational dashboards.
Challenges & How to Overcome Them
Of course, there are pitfalls. Ensuring scanning + modelling delivers value requires attention to:
Planning the scanning campaign (scan positions, control points, resolution) to avoid shadow zones or missing data.
Choosing hardware and equipment that can operate under plant conditions (dust, vibration, temperature, restricted access).
Processing & registration of point clouds, managing the large data sets, and ensuring clean, usable models.
Ensuring modelling workflow aligns with engineering design tools (CAD systems, formats, tolerances) so that the scan data is usable without excessive cleanup.
Maintaining the model: when plant layouts or equipment change, keeping the scan or model up to date so your decisions are based on recent reality.
At Hamilton By Design we emphasise these aspects; our scan-to-CAD workflows are built to align with plant engineering needs, and we help clients plan and manage the full lifecycle.
Real World Applications in Mining & Process Plants
Here’s how combined scanning + modelling is applied (and what you might look for in your own facility):
Wear & Relining: scanning mill, crusher liners, chutes or hoppers to model wear profiles; predict failures; design replacement parts that fit exactly.
Stockpile / Volumetric Monitoring: using scans or LiDAR to measure stockpile volumes for planning and reporting; integrating with models to monitor material movement and flow.
Safety & Clearance Checking: verifying that walkways, egress paths, platforms have maintained their clearances; assess structural changes; check for deformation or damage.
Shutdown Planning: using accurate 3D models to plan the scope, access, scaffold/frame erection, pipe removal etc., so shutdown time is minimised.
Why Choose Hamilton By Design
To get full value from the scan + model combination, you need more than just “we’ll scan it” or “we’ll make a model” — you need a partner who understands both the field realities and the engineering rigour. Here’s where Hamilton By Design excels:
Strong engineering experience in mining & processing plant settings, so we know what level of detail, what tolerances, and what access constraints matter.
Proven tools & workflows: from LiDAR / laser scanner work that captures site conditions even under harsh conditions, to solid CAD modelling/reporting that aligns with your fabrication/installation requirements.
Scan-to-CAD workflows: not just raw point clouds, but models that feed directly into design, maintenance, procurement and operations.
Focus on accuracy, safety, and reduced downtime: ensuring that field work, design, installation etc., are as efficient and risk-averse as possible.
Use of modern digital techniques (digital twins, clash detection etc.) so that data isn’t just stored, but actively used to drive improvements.
Practical Steps to Get Started / Best Practice Tips
If you’re managing a plant or engineering project, here are some steps to adopt scanning + modelling optimally:
Define Clear Objectives: What do you want from this scan + model? Wear profiles, retrofit, layout changes, safety audit etc.
Survey Planning: Decide scan positions, control points, resolution (density) based on the objectives and site constraints. Consider access, safety, shutdown windows.
Use Appropriate Hardware: Choose scanners suited to environment (dust, heat), also ensure regulatory and IP protection etc.
Data Processing & Modelling Tools: Have the capacity/software to register, clean, mesh or extract CAD geometry.
Integrate into Existing Engineering Processes: Ensure the outputs are compatible with your CAD standards, procurement, installation etc.
Iterate & Maintain: Frequent scans over time to track changes; update models when plant changes; feed maintenance, design and operations with new data.
Conclusion
In mining process plants, time, safety, and certainty matter. By combining 3D scanning with sound 3D modelling you don’t just get a snapshot of your plant — you gain a powerful toolset to reduce downtime, avoid rework, improve safety, and enhance decision-making.
If you’re responsible for uptime, capital works, maintenance or process improvements, this integration can reshape how you plan, maintain, and operate. At Hamilton By Design, we’re helping clients in Australia harness this power — turning reality into design confidence, and giving stakeholders peace of mind that the layout, equipment, and safety are aligned not to yesterday’s drawings but to today’s reality.
3D Laser Scanning & Mechanical Engineering Solutions
In today’s fast-paced engineering and construction industries, precision and efficiency are everything. Whether you’re managing a large-scale infrastructure project in Brisbane, creating a mechanical prototype in Perth, or needing accurate as-built data for a site in the Hunter Valley, 3D laser scanning and expert mechanical design services are game changers.
At Hamilton Design, we specialise in connecting cutting-edge scanning technology with skilled mechanical designers and structural drafting services to deliver seamless, accurate solutions for every stage of your project.
The Power of 3D Laser Scanning
3D laser scanning is transforming the way engineers, architects, and manufacturers work. By capturing millions of data points with millimetre accuracy, laser scanning creates a highly detailed 3D representation of your asset, site, or structure.
Our team provides 3D laser scanning services in Perth, Brisbane, and Melbourne, as well as laser scanning in the Hunter Valley, helping clients save time and avoid costly rework. This technology is ideal for:
Capturing as-built conditions before design or construction.
Supporting plant upgrades and facility expansions.
Documenting heritage structures and complex geometries.
Reducing site visits with accurate digital models.
Reverse Engineering & Mechanical Design
In addition to scanning, we offer reverse engineering services in Perth and beyond. By combining point cloud data with CAD modelling, we can recreate components, optimise designs, and prepare manufacturing-ready files.
Our mechanical engineers and mechanical designers bring years of experience in 3D mechanical engineering, design and manufacturing mechanical engineering, and problem-solving for a wide range of industries. From bespoke machinery to process equipment, we deliver solutions that work.
Structural Drafting & Project Support
No project is complete without clear, accurate documentation. Our skilled drafters in Hamilton and across Australia provide high-quality structural drafting services that integrate seamlessly with your workflows.
Whether you need shop drawings, fabrication details, or BIM-ready models, our team ensures every line and dimension is correct — saving you time and cost on-site.
Why Choose Hamilton Design?
Nationwide Reach: Serving clients with 3D scanning services in Perth, Brisbane, and Melbourne, and supporting projects in the Hunter Valley.
Complete Solutions: From scanning to modelling to mechanical engineering design.
Accuracy & Efficiency: Reduce project risk and improve decision-making with reliable data.
Experienced Team: Skilled mechanical engineers and drafters who understand your industry.
Ready to Get Started?
If you’re looking for mechanical engineering companies that deliver precision, innovation, and reliability, Hamilton Design is ready to help. Whether you need laser scanning in Perth or Brisbane, structural drafting, or full mechanical design services, our team can support your next project from concept to completion.
📞 Contact us today to discuss your project requirements and find out how our 3D laser scanning and mechanical engineering design solutions can save you time and money.
In today’s world, accuracy and efficiency can make or break a project. Whether you’re working in architecture, construction, engineering, or product design, you need reliable data — and you need it fast. That’s where 3D point clouds come in.
But there’s an important catch: not all scans are created equal. The difference between an average scan and a great one often comes down to the person behind the scanner. Having someone who understands 3D modeling take the scans can dramatically improve your project’s accuracy, reliability, and overall success.
Let’s break down why.
The Power of 3D Point Clouds
Point clouds are essentially millions of tiny data points that capture the shape of an object, room, or entire site. Together, they create a highly detailed digital snapshot of the real world.
Here’s why this matters:
Precision you can trust – Point clouds deliver incredibly detailed measurements, capturing even the smallest curves and angles.
Nothing gets missed – Multiple scan angles ensure a full, 360° view of your site or object.
Speed and efficiency – What used to take hours (or days) with manual measurements can be captured in minutes.
Built-in context – You’re not just getting numbers; you’re getting a complete digital environment to work inside.
Future-proof data – Once you have a scan, you have a permanent record of your space, ready to use months or years later.
From clash detection to as-built verification, point clouds save time, reduce errors, and make collaboration across teams smoother than ever.
Why the Person Taking the Scan Matters
While technology is powerful, experience is what makes the results reliable. Having a skilled 3D modeler operate the scanner can be the difference between a good project and a great one.
Here’s why an expert makes all the difference:
They know what matters – A modeler understands which details are critical for your project and ensures they’re captured.
Fewer gaps, fewer surprises – Experienced pros know how to plan scan positions to cover every angle and avoid blind spots.
Cleaner, more accurate data – They reduce common issues like noise, misalignment, or missing sections that can throw off your model.
Time saved, headaches avoided – No one wants to redo a scan halfway through a project. A professional ensures you get it right the first time.
Confidence from start to finish – When you know your model is accurate, you can move forward with design and construction decisions without second-guessing.
In short: a great scanner operator doesn’t just deliver data — they deliver peace of mind.
The Bottom Line
3D point clouds are already transforming how projects are planned and delivered. But pairing them with an experienced 3D modeler takes things to the next level.
You’ll get better data, faster turnarounds, and a far lower risk of costly mistakes. And when your goal is to deliver projects on time, on budget, and with zero surprises, that’s an edge you can’t afford to miss.
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.
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.
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.
🖥 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.
