Mechanical Design: Mechanical Design: Mechanical Design

Mechanical Design: Mechanical Design: Hamilton By Design offer a range of effective mechanical design services through MCAD (Mechanical Computer Aided Design) Drafting and 3D So...

Mechanical Design: Foundations of Precision & Performance

In mechanical engineering, design is more than drafting parts—it’s converting ideas and requirements into physical reality. At Hamilton By Design, our mechanical design services move beyond aesthetic sketches. We focus on mechanical systems that are robust, adaptable, and built to perform in real environments.

Mechanical design bridges concept and construction. It integrates loads, kinematics, tolerances, materials, manufacturability, maintenance, and cost. A great design anticipates problems and solves them before they arise.

Below I rewrite and elaborate on core principles of mechanical design—what we do, how we think, and where we drive real value in projects.

What Mechanical Design Means for Us

When we say “mechanical design,” here's what we're offering:

Mechanical Computer-Aided Design (MCAD) drafting and modelling
3D parametric component and assembly modelling
Structural / frame design and support systems
Kinematic/mechanism layout: linkages, actuators, constraints
Design optimisation: mass, stiffness, manufacturable geometry
Integration of mechanical with other systems (pipes, electrical, structure)

We don’t just hand over models—we deliver design intelligence: geometry that reflects function, constraints, and future evolution.

Key Principles in Mechanical Design

1. Design Intent & Parametric Logic

A good mechanical design isn’t static. We build models so that when you change one parameter (length, thickness, hole offset), dependent features update automatically. This is design intent. It reduces error, enables iteration, and gives flexibility when requirements evolve.

2. Load Paths and Structural Clarity

Every force, moment, or load must trace a clear path through structure. We define beams, gussets, webs, stiffeners such that loads always flow logically, avoiding hidden stress concentrations or weak linkages. That clarity separates reliable structures from ones that fail under complexity.

3. Manufacturability & Real-World Constraints

Designs must be buildable. That means respecting material limits, weld access, standard sections, stock sizes, tolerances, and fabrication allowances. We embed those constraints early—not after the fact—so your design is both ideal and real.

4. Serviceability & Maintenance

A design that can’t be serviced fails in practice. We plan for access, clearance, removal of parts, adjustment, alignment—all before the first weld. A structure only lives if it can be maintained.

5. Validation & Simulation

Every design is verified: stress, deflection, vibration, buckling, fatigue—these are not optional add-ons. Using analysis tools, we test the design digitally so that we uncover potential failures long before physical fabrication.

Integrating 3D Scanning & Real-World Geometry (Modern Twist)

In modern mechanical design, theory meets reality through 3D scanning. Suppose your next project involves existing plant geometry, aged structures, or legacy equipment. You can’t rely on ideal drawings alone. You need the real object.

We use LiDAR or structured-light scanning to capture the physical as-built geometry. That produces a point cloud: millions of spatial points representing every surface, alignment, curvature, and deformation present on-site. From that, we extract surfaces, curves, and reference geometry, and we feed them into our parametric models.

This synergy—scanning + modelling—ensures:

Accurate alignment of new parts with existing structures
Elimination of interference or clash surprises in 3D space
Better validation because simulation takes into account real geometry, not ideal assumptions
Future adaptability as your model remains tied to real structure, capable of updates and retrofit

Thus, mechanical design becomes grounded in reality, not abstraction.

A Project Workflow: From Scan to Structure

Here’s how a typical project might flow:

Site scanning – Capture environment, structural surfaces, beams, walls, mounting points.
Point-cloud processing – Clean noise, register scans, segment relevant surfaces.
Reverse geometry – Extract planes, curves, surfaces to act as references.
Parametric modelling – Create components and assemblies in CAD (Inventor, SolidWorks, AutoCAD) referencing scanned surfaces.
Structural analysis – Run stress, deformation, vibration analysis using that model.
Clash & fit checking – Confirm your design doesn’t conflict with scanned elements.
Deliverables – Detailed drawings, 3D models, fabrication data, alignment plans.
Field verification – Optionally rescan after installation to compare as-built to model.

This ensures the design is not just theoretical — it’s validated in context.

Real-World Examples Where This Matters

Retrofitting existing plants — Many sites have decades of drift, distortion, or undocumented modification. Scanning gives you reality; your design respects it.
Structural frame additions — You attach new beams or platforms to old structures. If your geometry is off by millimetres, you risk misalignment or onsite rework.
Equipment relocation / installation — When moving or adding machinery, the mounting frame must exactly fit existing foundations, clearances, and support structures.
Wear and replacement design — Scanning worn-out surfaces or parts allows you to rebuild replacements that match precisely, rather than guessing tolerances.

Challenges and Solutions

Challenge	How We Solve
Noisy scan data or misregistering	Use multiple passes, robust registration algorithms, manual correction where needed
Incomplete or occluded areas in scans	Supplement scanning with manual measurement and inference
Translating free-form surfaces into parametric features	Use hybrid modelling or careful surface fitting
Ensuring simulation meshes cleanly on scanned geometry	Simplify geometry or use representative surfaces for analysis
Managing large model sizes and performance	Use lightweight references, region-of-interest modelling, and CAD discipline