Why Shutdown Parts Don’t Fit — And How 2 mm LiDAR Scanning Stops the Rework

When Parts Don’t Fit, Shutdowns Fail

Every shutdown fitter, maintenance crew member, and supervisor has lived the same nightmare:

A critical part arrives during shutdown.
The old part is removed.
Everyone gathers, ready to install the new one.
Production is waiting.
The pressure is on.

And then—
the part doesn’t fit.

Not 2 mm out.
Not 10 mm out.
Sometimes 30–50 mm out, wrong angle, wrong bolt pattern, wrong centreline, or wrong geometry altogether.

The job stops.
People get frustrated.
Supervisors argue.
Fitters cop the blame.
The plant misses production.
And someone eventually says the words everyone hates:

“Put the old worn-out chute back on.”

This blog is about why shutdowns fall apart like this… and how 2 mm LiDAR scanning finally gives fitters a system that gets it right the first time.

The Real Reason Parts Don’t Fit

Most shutdown failures have nothing to do with the fitter, nothing to do with the workshop, and nothing to do with the installation crew.

Parts don’t fit because:

Wrong measurements
Bad drawings
Outdated as-builts
Guesswork
Fabricators “eyeballing” dimensions
Cheap non-OEM parts purchased without geometry verification
Designers who have never seen the site
High staff turnover with no engineering history
Wear profiles not checked
Intersection points impossible to measure manually

Fitters are then expected to make magic happen with a tape measure and a grinder.

It’s not fair. It’s not professional. And it’s completely avoidable.

Shutdown Pressures Make It Even Worse

When a part doesn’t fit during a shutdown:

The entire job stalls
Crews stand around waiting
The supervisor gets hammered
The fitter gets the blame
Other shutdown tasks cannot start
The clock ticks
Production loses thousands per hour
Everyone becomes stressed and angry

And the worst part?

You were only replacing the part because the existing one was worn out.
Now you’re bolting the worn-out one back on.

This isn’t good enough.
Not in 2025.
Not in heavy industry.
Not when there is technology that eliminates this problem completely.

Why Manual Measurement Fails Every Time

Fitters often get asked to measure:

Inside chutes
Wear sections
Pipe spools with intersection points
Tanks too large to measure from one position
Walkways too long for tape accuracy
Geometry with no records
Components 10+ metres above ground
Hard-to-reach bolt patterns
Angles and centrelines distorted by wear

But some measurements simply cannot be taken safely or accurately by hand.

You can’t hang off an EWP 20 metres up measuring a worn flange angle.
You can’t crawl deep inside a chute trying to measure intersecting surfaces.
You can’t take a 20-metre walkway measurement with a tape measure and hope for precision.

This is not a measurement problem.
This is a method problem.

Manual measurement has hit its limit.
Shutdowns have outgrown tape measures.

This Is Where 2 mm LiDAR Scanning Changes Everything

Hamilton By Design uses 2 mm precision LiDAR scanning to capture the exact geometry of a site — even in areas that are:

Too high
Too big
Too unsafe
Too worn
Too complex
Too tight
Too distorted to measure manually

From the ground, up to 30 metres away, we can capture:

Wear profiles
Flange positions
Bolt patterns
Pipe centrelines
Chute geometry
Conveyor interfaces
Complex intersections
Ductwork transitions
Mill inlet/outlet shapes
Tank dimensions
Walkway alignment
Structural deflection
Existing inaccuracies

No tape measure. No guesswork. No EWP. No risk.

The result is a perfect 3D point cloud accurate within 2 mm — a digital version of real life.

2 mm Scanning + Fitter-informed Design = Parts That Fit First Time

This is where Hamilton By Design is different.

We don’t just scan and hand the files to a drafter who’s never set foot on-site.

We scan and your parts are modelled by someone who:

Has been a fitter
Understands how parts are installed
Knows what goes wrong
Knows how to design parts that actually fit
Knows where shutdowns fail
Knows what to check
Knows what NOT to trust
And most importantly — knows where the real-world problems are hidden

This fitter-informed engineering approach is why our parts fit the first time.

And why shutdown crews trust us.

Digital QA Ensures Fabrication Is Correct Before It Leaves the Workshop

Once the new chute, spool, or component is modelled, we run digital QA:

Fit-up simulation
Clash detection
Tolerance analysis
Wear profile compensation
Reverse engineering comparison
Bolt alignment verification
Centreline matching
Flange rotation accuracy
Structural interface checks

If something is out by even 2–3 mm, we know.

We fix it digitally — before the workshop cuts steel.

This stops rework.
This stops shutdown delays.
This stops blame.
This stops stress.

This is the future of shutdown preparation.

Accuracy of 3D LiDAR Scanning With FARO

When the Part Fits, Everything Runs Smooth

Here’s what actually happens when a chute or spool fits perfectly the first time:

The plant is back online faster
No rework
No reinstalling old worn-out parts
No arguing between fitters and supervisors
No unexpected surprises
No extra access equipment
No late-night stress
No grinding or “making it fit”
Other shutdown tasks stay on schedule
Everyone looks good
Production trusts the maintenance team again

Shutdowns become predictable.
Fitters become heroes, not last-minute problem-solvers.

Shutdown Example (Anonymous but Real)

A major processing plant needed a large chute replaced during a short shutdown window.
Access was limited.
The geometry was distorted.
Measurements were impossible to take safely.
The workshop needed exact dimensions, fast.

Hamilton By Design scanned the entire area from the ground — no EWP, no risk.

We produced:

Full 2 mm point cloud
As-built 3D model
New chute design
Digital fit-up validation
Workshop-ready drawings

The new chute arrived on site.
The old chute came out.
The new chute went straight in.
Zero rework.
Zero stress.
Plant online early.

The supervisor called it the smoothest shutdown they’d had in 10 years.

Why Fitters Should Reach Out Directly

Sometimes fitters know more about what’s really happening on-site than anyone in the office.

Fitters see the problems.
Fitters carry the blame.
Fitters deal with the rework.
Fitters just want parts that fit.

So we’re making this simple:

If you’re tired of fitting parts that don’t fit —
If you’re tired of fixing other people’s mistakes —
If you’re tired of shutdown stress —

Call Hamilton By Design.

We scan it.
We model it.
We get it right.
Every time.

Services Featured

Hamilton By Design offers:

3D LiDAR laser scanning (2 mm precision)
3D modelling by a fitter-engineer who understands real-world installation
Digital QA before fabrication
Reverse engineering of worn components
Shutdown planning support
Fabrication-ready drawings
Fit-up simulation
Clash detection between old and new parts

This is how shutdowns run smooth.

Call to Action

Are you a Fitter: tired of parts that don’t fit?

Email or Call Hamilton By Design.

Email – info@hamiltonbydesign.com.au

Phone – 0477002249

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Accuracy of 3D LiDAR Scanning With FARO

Why Shutdown Parts Don’t Fit

Engineering Services

Coal Chute Design

Chute Design

3D CAD Modelling | 3D Scanning

7 November 202514 January 2026

Stop Reacting — Start Engineering

How Smart Mechanical Strategies Extend CHPP Life

Every coal wash plant in Australia tells the same story: constant throughput pressure, harsh operating conditions, and the never-ending battle against wear, corrosion, and unplanned downtime. The reality is simple — if you don’t engineer for reliability, you’ll spend your time repairing failure.

At Hamilton By Design, we specialise in mechanical engineering, 3D scanning, and digital modelling for coal handling and preparation plants (CHPPs). Our goal is to help site teams transition from reactive maintenance to a precision, data-driven strategy that keeps production steady and predictable.

Workers guiding a crane-lifted yellow chute into position at a coal handling and preparation plant, with conveyor infrastructure and safety equipment visible on site

Design for Reliability — Not Reaction

Reliability begins with smart mechanical design. Poor geometry, limited access, and undersized components lead to fatigue and repeated downtime. Instead, modern CHPP maintenance programs start by engineering for fit, lift, and life:

Fit: Design components that align with the existing structure — every bolt, flange, and mating face verified digitally before fabrication.
Lift: Incorporate certified lifting points that comply with AS 4991 Lifting Devices, and ensure clear access paths for cranes or chain blocks.
Life: Select wear materials suited to the physics of the process — quenched and tempered steel for impact, rubber or ceramic for abrasion, and UHMWPE for slurry lines.

It’s not just about parts; it’s about engineering foresight. A well-designed plant component is safer to install, easier to inspect, and lasts longer between shutdowns.

Scan What You See — Not What You Think You Have

Over time, every wash plant drifts from its original drawings. Field welds, retrofits, and corrosion mean that “as-built” and “as-exists” are rarely the same thing.

That’s where LiDAR scanning transforms maintenance. Using sub-millimetre accuracy, 3D laser scans capture your plant exactly as it stands — every pipe spool, every chute, every bolt hole.

With this data, our engineers can:

Overlay new models directly into your point cloud to confirm fit-up before fabrication.
Identify alignment errors, corrosion zones, and clearance conflicts before shutdowns.
Generate true digital twins that allow for predictive maintenance and simulation.

LiDAR scanning isn’t just a measurement tool; it’s an insurance policy against rework and lost production.

3D LiDAR point cloud of a CHPP plant showing detailed structural geometry, equipment, platforms, and personnel captured during an industrial site scan for engineering and upgrade planning.

Corrosion: The Hidden Killer in Every CHPP

Coal and water don’t just move material — they create acidic environments that eat through untreated or aging steel. In sumps, launders, and under conveyors, corrosion silently compromises strength until a structure is no longer safe to walk on.

Regular inspections are the first line of defence. At Hamilton By Design, we recommend combining:

Daily visual checks by operators for surface rust and coating damage.
Thickness testing during shutdowns to track wall loss on chutes and pipes.
3D scan comparisons every 6–12 months to quantify deformation and corrosion in critical structures.

With modern tools, you can see corrosion coming long before it becomes a failure.

From Data to Decision: Predictive Maintenance in Action

A coal wash plant produces a river of data — motor loads, vibration levels, pump pressures, liner thickness, and flow rates. The key is turning that data into insight.

By integrating scanning results, maintenance records, and sensor data, plant teams can identify trends that point to future breakdowns. For example:

Vibration trending can reveal bearing fatigue weeks before failure.
Load monitoring can detect screen blinding or misalignment.
Scan data overlays can show sagging supports or displaced chutes.

When you understand what your plant is telling you, you move from reacting to problems to predicting and preventing them.

Industrial shutdown scene showing workers monitoring a mobile crane lifting a large steel chute inside a coal processing plant, with safety cones and exclusion zones in place

Shutdowns: Planned, Precise, and Productive

Every shutdown costs money — the real goal is to make every hour count. The best shutdowns start months ahead with validated design data and prefabrication QA.

Before you cut steel or mobilise cranes, every component should be digitally proven to fit. Trial assemblies, lifting studies, and bolt access checks prevent costly surprises once you’re on the clock.

At Hamilton By Design, our process combines:

LiDAR scanning to confirm as-built geometry.
SolidWorks modelling and FEA for mechanical verification.
Pre-installation validation to ensure bolt holes, flanges, and lift paths align on day one.

That’s how you replace chutes, spools, and launders in a fraction of the usual time — safely, and with confidence.

Hand-drawn infographic showing the shutdown workflow from LiDAR scanning and FEA verification through SolidWorks modelling, pre-install validation, trial assembly, lift study, and execution, including ITP and QA checks, safety steps, and onsite installation activities

The Payoff: Reliability You Can Measure

The plants that invest in engineering-led maintenance see results that are tangible and repeatable:

Improvement Area	Typical Gain
Reduced unplanned downtime	30–40%
Increased liner lifespan	25–50%
Shorter shutdown duration	10–20%
Fewer fit-up issues and rework	60–80%
Improved safety performance	20–30%

Reliability isn’t luck — it’s engineered.

Your Next Step: A Confidential Mechanical Assessment

Whether your plant is in the Bowen Basin, Hunter Valley, or Central West NSW, our team can deliver a confidential mechanical and scanning assessment of your wash plant.

We’ll benchmark your current maintenance strategy, identify high-risk areas, and provide a clear roadmap toward predictive, engineered reliability.

📩 For a confidential assessment of your current wash plant, contact:
info@hamiltonbydesign.com.au

Stop reacting. Start engineering. Build reliability that lasts.

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Mechanical Engineering | Structural Engineering

Mechanical Drafting | Structural Drafting

3D CAD Modelling | 3D Scanning

Chute Design

1 November 202514 January 2026

Stop Guessing, Start Scanning: How 3D Laser Scanning Prevents Costly Shutdown Delays

The Cost of Guesswork in Shutdowns

Every shutdown comes with pressure — time, budget, and safety. When mechanical upgrades or maintenance are based on outdated drawings or manual measurements, the risk of error skyrockets. A misaligned chute, an incorrectly measured pipe, or a bracket that doesn’t quite fit can turn a planned three-day outage into a five-day scramble.
In industries where every hour offline costs tens of thousands of dollars, guesswork is expensive.

Illustrated scene showing a 3D laser scanner capturing an industrial plant while engineers observe and review data, highlighting how scanning prevents costly shutdown delays.

3D Laser Scanning: Seeing the Plant as It Really Is

That’s where 3D laser scanning and LiDAR technology change the game. Using a FARO or similar high-accuracy scanner, Hamilton By Design captures millions of data points in a matter of minutes — creating a precise digital replica of your plant or structure.
This point cloud model forms the foundation for all design work. Every pipe, beam, and bracket is located exactly where it exists in the real world, not where an old drawing says it should be.

From Scan to SolidWorks: Accurate Models, Confident Designs

Once the scan is complete, the data is reverse-modelled into SolidWorks or similar 3D design environments.
This means upgrades, chutes, handrails, and structural supports can be designed within the scanned environment — guaranteeing they fit perfectly on installation day.
Our clients use this workflow to plan shutdowns with confidence, knowing that every fabricated part will bolt straight in.

Eliminating Fit-Up Errors and Rework

Traditional upgrade projects rely on tape measures, rough sketches, or outdated general arrangement drawings. Even a 10 mm error can cause weeks of rework once site access is restricted.
With 3D scanning, those errors disappear.
Before fabrication begins, engineers can check for:

Clashes and interferences between new and existing plant structures.
Clearances for maintenance and access.
Alignment with conveyors, supports, and existing chutes.

That level of insight is impossible with 2D drawings alone.

Shorter Shutdowns, Safer Teams

Fewer surprises mean faster, safer installations.
When every component is designed and verified within the scanned model, shutdown crews spend less time cutting, grinding, or reworking in the field.
That’s not only a productivity win, it’s a safety win — fewer sparks, less manual handling, and minimal hot work in confined spaces.

Applications Across Mining and Processing

Hamilton By Design’s scanning and modelling process is trusted across the Bowen Basin, Surat Basin, Hunter Valley, and Central West NSW.
Typical projects include:

CHPP upgrades — chute replacements, diverter modifications, and screen structure changes.
Conveyor realignments — ensuring belt runs are perfectly centred before shutdown.
Pipework and pump station retrofits — avoiding rework when tie-ins occur.
Structural verification — validating as-built conditions before new platforms or walkways are installed.

FARO 3D laser scanner set up on a tripod capturing an industrial plant for LiDAR scanning and digital modelling, with Hamilton By Design branding in the corner.

Real-World ROI

Clients routinely report saving days of downtime and thousands in rework costs by scanning before fabrication.
When you consider that a typical CHPP shutdown might cost $20,000–$50,000 per hour in lost production, the return on investment is obvious.
A few hours spent scanning can mean days of avoided delay.

Stop Guessing, Start Scanning

If your next shutdown involves tight spaces, limited access, or unknown conditions — don’t rely on old drawings or assumptions.
Hamilton By Design provides LiDAR scanning, point-cloud modelling, and SolidWorks-based mechanical design to ensure your upgrades install exactly as intended.

👉 Book a site scan before your next shutdown.
Visit www.hamiltonbydesign.com.au or contact us to discuss your upcoming project.

3D CAD Modelling | 3D Scanning

Chute Design

Mechanical Engineering | Structural Engineering

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`3D LiDAR Scanning and 3D Modelling – Hamilton By Design`

SolidWorks

As-Built Drawings from a LiDAR Scanner

25 October 202527 January 2026

Integrating 3D Scanning and Mechanical Design for Safer, Faster Upgrades in Coal Wash Plants

Precision Without the Guesswork

Upgrading or maintaining a coal wash plant has always been a challenge — tight shutdown windows, complex layouts, and the need for perfect fit-ups between new and existing components. Traditional measurement methods, like tape measures and manual sketches, are often impossible in restricted or hazardous areas.

That’s where 3D scanning and mechanical engineering come together. At Hamilton By Design, we combine precision laser scanning, intelligent 3D modelling, and practical mechanical design to deliver risk-free upgrades — ensuring every component fits right the first time.

Infographic showing how 3D scanning and 3D modelling feed into mechanical design for safer, faster upgrades at a coal wash plant, with icons representing scanning, modelling, and engineering drawings

When Accuracy Matters Most

Coal wash plants are intricate systems. From cyclones, screens, and diverter chutes to pumps, piping, and structures, every part interacts under tight tolerances. A small misalignment can lead to vibration, spillage, or shutdown delays.

Our 3D scanning process captures millions of spatial data points, creating a detailed digital twin of the existing plant. This allows us to model upgrades, design replacement components, and simulate fit-up — all before fabrication begins.

In many cases, scanning replaces the need to physically measure equipment. For example, in confined or high-risk spaces where a tape measure simply can’t reach, scanning provides complete, line-of-sight geometry with millimetre accuracy.

Recently, our team scanned a diverter chute that had been incorrectly installed. The resulting model revealed that the chute had been fitted in the wrong orientation — explaining why it wasn’t sealing properly. This insight helped our client avoid further downtime and costly rework.

Combining Engineering Experience with Digital Precision

Hamilton By Design provides a full suite of mechanical engineering services tailored to the mining industry, including:

3D Scanning & Point Cloud Capture – detailed mapping of existing equipment and structures
3D Modelling & Reverse Engineering – accurate, editable digital models
Mechanical Design & Structural Replacement – like-for-like component upgrades
Piping Routes & Spool Fabrication – optimised pipe design and layout
Fabrication & Component Drawings – compliant with Australian Standards and client templates

Our engineers work across SolidWorks, AutoCAD Plant 3D, Revit, and 3D Experience platforms — integrating point cloud data directly into the design workflow. This means fewer site visits, fewer surprises, and significantly less rework once fabrication begins.

From Drawings to Digital Models

We’ve evolved beyond traditional 2D general arrangement drawings. Instead, we provide interactive 3D models and e-drawings that allow clients, fabricators, and site teams to visualise how upgrades will fit within the plant.

Our reverse cloud modelling process inserts 3D designs directly into the scanned environment. This enables engineers and site teams to measure potential interferences, check clearances, and validate installation methods — long before shutdowns begin.

Illustrated workflow showing how 2D GA drawings and scanned environments are turned into 3D digital models through reverse cloud modelling and eDrawings, demonstrating confidence in fabrication fit for mining and industrial equipment.

The result = Confidence.
Every pipe spool, chute, and bracket is designed to fit — without compromise.

Supporting Contractors and Plant Operators

We partner with:

Mining companies operating coal wash plants
Fabricators and contractors supplying mining equipment
Maintenance providers planning plant shutdowns

Their biggest challenge is finding people who design for fit and function — not just form. Not all CAD or point cloud software is equal, and not every designer understands the realities of on-site installation. That’s where Hamilton By Design stands apart.

We bring hands-on mechanical trade experience, engineering design expertise, and digital technology together — helping your team deliver upgrades that work, first time.

Built to Australian Standards

All design and drawing deliverables are completed in accordance with Australian Standards, ensuring compliance, safety, and interoperability with existing documentation.

We can also supply fabrication drawings on client-specific templates, maintaining intellectual property (IP) requirements and formatting standards.

Servicing Australia’s Key Mining Regions

Hamilton By Design proudly supports coal wash plant upgrades and mechanical design projects across Australia’s leading coal regions, including:

Bowen Basin
Surat Basin
Hunter Valley
Newcastle
Central Coast
Western and Central NSW coalfields

Our local experience ensures that we understand the logistical, operational, and environmental challenges unique to each region — helping projects stay compliant, efficient, and on schedule.

Accuracy of 3D LiDAR Scanning With FARO

3D Scanning Sydney

Mechanical Engineering

Why Choose Hamilton By Design?

Reduced Downtime: Accurate pre-shutdown planning through digital models.
Improved Safety: Less manual measuring in hazardous or confined areas.
Guaranteed Fit-Up: Fabrication drawings verified against real-world geometry.
Faster Turnaround: Streamlined scanning-to-design-to-fabrication workflow.
Proven Experience: Over two decades in mechanical engineering and plant design.

Our mission is simple — to take the risk out of upgrades by combining engineering insight with digital accuracy.

Quote

“Precision scanning and mechanical design — taking the risk out of plant upgrades.”

Let’s Make Your Next Upgrade Risk-Free

If your next shutdown involves mechanical upgrades, pipework replacement, or structural modifications, talk to Hamilton By Design.

We can help you visualise, plan, and execute upgrades with confidence — reducing downtime, eliminating measurement errors, and delivering safer outcomes for your team.

info@hamiltonbydesign.com.au
www.hamiltonbydesign.com.au

Mechanical Drafting | Structural Drafting

3D CAD Modelling | 3D Scanning

Chute Design

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3D laser Scanning for Engineering

3D laser Scanning Buildings

3D Construction Scan

20 October 202514 January 2026

Building with Precision: 3D Scanning and LiDAR Modelling for Sydney Construction Projects

Accuracy That Builds Sydney Better

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.

Illustrated infographic showing 3D scanning and LiDAR modelling for Sydney construction, from site scanning and point-cloud creation to BIM modelling and fabrication, highlighting millimeter accuracy, no rework, faster installation, improved safety, and better documentation

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.

Mechanical Engineers in Sydney

Mechanical Engineering | Structural Engineering

3D Scanning Sydney

Engineering Services

get in touch

sales@hamiltonbydesign.com.au

Based in Sydney — servicing Chatswood, Parramatta, and the Eastern Suburbs
info@hamiltonbydesign.com.au
www.hamiltonbydesign.com.au

Capture. Model. Verify. Deliver.
Hamilton By Design — ensuring every project across Sydney fits perfectly, down to the last millimetre.

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20 October 202514 January 2026

Building Sydney Smarter: How 3D Scanning and LiDAR Are Transforming Construction Accuracy

A New Era of Construction Accuracy in Sydney

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.

Mechanical Engineers in Sydney

Mechanical Engineering | Structural Engineering

3D Scanning Sydney

Engineering Services

get in touch

sales@hamiltonbydesign.com.au

Based in Sydney — working across NSW and Australia
info@hamiltonbydesign.com.au
www.hamiltonbydesign.com.au

Capture. Model. Verify. Deliver — precision that builds Sydney better.