Mechanical Design: Mechanical Design: mechanical structural design

Mechanical Structural Design Reimagined: Scanning, Modelling, and Structural Integrity

Mechanical and structural design has long been the backbone of engineering systems — load paths, frame members, support plates, welds, beam geometry, tolerance stacks. But traditional design workflows often start in abstraction, divorced from the real environment where the system must live.

Today, that approach is changing. With 3D scanning, point-cloud capture, and parametric modelling, engineers can start from reality. Then, using CAD platforms like Inventor, AutoCAD, or SolidWorks, they overlay design intent, simulation, and structural optimization — building designs that not only “look good on paper” but truly fit and perform in the real world.

This post explores how Hamilton By Design bridges the physical and the digital: merging mechanical/structural design with point-cloud modelling to deliver engineered solutions you can trust.

The Traditional Gap: Abstract Design vs Physical Reality

Engineers often begin structural designs by referencing drawings, sketches, or legacy CAD data. The challenge? Everything in the field drifts over time:

Structural frames sag or deform
Weldments distort
Bolt holes shift
Existing steel members corrode or change geometry

When your new design assumes “perfect geometry,” you risk misalignment, interference, or rework once you get to site. Too often, field crews discover that the new structure doesn’t quite fit — because real-world data was never captured.

Enter 3D Scanning and Point-Clouds: Capturing “What Is”

LiDAR scanning or structured-light scanners let you capture millions of spatial points — a point cloud — reflecting the actual existing geometry. This gives you:

Surface profiles, curvature, offsets
Dimensional distortions and wear
Reference baseline for retrofit or extension

You don’t guess or approximate. You measure.

Once you have that point cloud, you can:

Align and register scans from multiple viewpoints
Clean noise, filter redundant points, and segment surfaces
Use surface fitting tools to extract planes, curves, lofts, and solids
Export those as reference geometry or base CAD surfaces

Now your design begins from where things truly are, not where they were intended to be.

Modelling in Inventor, AutoCAD, or SolidWorks: Where Design Takes Shape

With your reference geometry pulled from scan data, you can begin parametric design in any of the major CAD platforms. The specifics differ, but the goals remain consistent:

Parametric constraints & relations: Make the model flexible, with design intent encoded in dimensions, mates, and variables.
Assembly context: Position new parts in context of scanned reference structures — ensure fit, clearances, motion compatibility.
Structural modelling: Define load-bearing members, cross-sectional geometry, weld details, stiffeners, etc.
Simulation readiness: Organize geometry so it can be exported for FEA checks (stress, deflection, vibration) easily.
Manufacturing output: Generate drawings, BOMs, detail sheets, and CNC-ready geometry — all aligned with the true as-built base.

Because your new model is grounded in real surfaces, you avoid frustrating fit clashes and alignment surprises in the shop or field.

Case Workflow: From Scan to Structural Design

Here’s a typical project flow we use at Hamilton By Design:

Project kickoff and scope review
We identify which portions need scanning, which models must interface, critical tolerances, and load requirements.
Field scanning
We scan existing infrastructure (frames, supports, chute linings, foundations) using LiDAR or structured-light scanning tools.
Point-cloud processing
Multiple scans are aligned (registered), noise filtered, unnecessary points removed, and surfaces segmented.
Reverse geometry extraction
Extract planar, curved, lofted surfaces or reference features from the cleaned point cloud. These become your "digital shell."
Parametric modelling overlay
In Inventor / SolidWorks / AutoCAD (depending on client or consortium), we build new structural parts, mates, and assembly constraints referencing the extracted geometry.
Structural validation
From the model, export to FEA (static, modal, thermal as needed) or use embedded simulation features to test stresses, deflection, natural frequencies, and buckling behavior.
Fit & interference checks
Use interference detection tools to confirm that the new parts do not clash with scanned geometry or adjacent systems.
Detailed deliverables
Generate shop drawings, exploded views, weld schedules, and integration documentation — all referencing both new model and original surfaces.
Field alignment & calibration
Use the same scan tools post-installation to verify how closely the build aligns to model, then issue adjustments or corrections.

Structural Design Considerations in This Context

When building mechanical/structural systems over scanned bases, engineers must focus on several extra factors:

1. Tolerances & Fit Bands

Scanned geometry isn’t perfect — there’s noise and minor deviations. It’s critical to decide fit zones (e.g. ±1 mm) rather than forcing rigid adjacency.

2. Stiffness, Loads & Load Path Integrity

Just because something fits doesn’t mean it’s structurally sound. Cross-section sizing, deflection allowances, shear, bending, and frequency response remain critical.

3. Thermal and Differential Expansion

Structures expand and contract differently. Reference geometry must accommodate allowable tolerances — especially in long spans, high-temperature zones, or outdoor environments.

4. Sequencing & Installation Strategy

For assemblies built in place, model planning must consider sequence: which components bolt first, alignment features, jigs, and field adjustability.

5. Service Access & Maintenance

Scan data helps reveal actual proximity of maintenance zones, pipe routes, walkways, and clearance gaps — letting mechanical designers plan access from day one.

Benefits You Can Realize

Drastic reduction in field rework & misfit issues
Improved design confidence, especially around complex or aging structures
Faster project turnaround thanks to upstream validation
Lifecycle data continuity — models evolve as the plant or structure changes
Better stakeholder alignment — visual 3D models overlaid on real backgrounds aid review, assembly, and commissioning

Challenges & Best Practices

Challenge	Mitigation
Noisy point-clouds	Aggressive filtering, segmentation, and conservative surface fitting
Occluded areas	Multiple scans from different angles plus manual measurement
Complex geometry translation	Use hybrid modelling (parametric + freeform) and simplify where necessary
CAD performance	Use region-of-interest extraction and lighter reference geometry
Tolerance management	Use best-fit algorithms and build acceptable deviation bands

Why You Want a Partner Like Hamilton By Design

We combine three core competencies:

Field scanning & data capture by skilled mechanical engineers
Structural & mechanical modelling expertise, from base frame members to integration
Analysis-minded design, ensuring performance and safety, not just fit

When you work with us, you’re not just getting drawings — you’re getting a design environment rooted in reality and engineered for longevity, adaptability, and integration.

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3D CAD Modelling | 3D Scanning

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