Mechanical Design: April 2012

Sunday, April 1, 2012

Mechanical Design: Mechanical Design: mechanical structural design

: Mechanical Design: mechanical structural design: Mechanical Design: mechanical structural design : www.hamiltonbydesign.com.au

Mechanical Design Reinvented: The Power of 3D Modelling & Scanning

Mechanical design was once all about sketches, 2D layouts, and heuristics.
Today, the frontier is data, precision, and integration.
At Hamilton By Design, we believe truly smart mechanical design begins where 3D modelling meets reality capture — where digital representations are born from scanning the physical world itself.

This post reframes traditional mechanical design into a dynamic, data-driven process — one that starts in the real world and iterates inward.

From 2D to Digital Truth: Why 3D Matters

When a design exists only in 2D — blueprint views, elevation sketches, or abstract sections — much is left to interpretation. Ambiguities slip in: hidden geometry, assembly tolerances, interference, and real-world alignment all lurk off the page.

Switching to 3D modelling changes that. Now your design is spatial, parametric, and interconnected:

All views resolve to one coherent model — no mismatched dimensions.
Features, relationships, mates, and constraints become first-class objects.
Modification is fluid — change one parameter, and dependent features update automatically.
Visualisation is instantaneous — clash detection, clearance checks, collision detection — all become part of your design loop.

But 3D modelling isn’t enough by itself — if your model is based on assumptions rather than how the world actually is, you still risk misfit.

That’s where 3D scanning / LiDAR comes in.

Reality Capture: LiDAR & 3D Scanning as Ground Truth

Imagine walking into a site — a plant, a mine, a structural frame — with outdated drawings, worn parts, and unknown wear. You need to design a retrofit or modulo, but how do you know what’s really there?

LiDAR scanning solves that by capturing point clouds — spatial coordinates of millions of points — representing the actual surfaces and forms. From there:

You build reference surfaces that reflect what exists, not what was drawn.
You reconstruct curvatures, offsets, distortions, and deformations into CAD geometry.
You overlay new design geometry in perfect alignment with reality.

Now your model doesn’t imagine environment — it fits it.

Integrating Scan + Model: The Workflow

Here’s the integrated pipeline we use:

Scan the environment using LiDAR or structured-light scanners, capturing high-density spatial data.
Process the raw point cloud: cleaning noise, registering multiple scans, filtering.
Feature extraction & reverse modelling: convert selected surfaces, curves, solids into editable CAD geometry.
Parametric modelling: build features, define constraints, assemble parts in context.
Validation & simulation: run FEA, vibration, fit checks, tuft tests.
Delivery & iteration: deliver models, drawings, and as-built data; rescan later for lifecycle updates.

That workflow ensures design fidelity from field to factory.

Real-World Applications

Mining Chutes & Material Systems
Scans reveal wear, warpage, liner erosion. We rebuild true geometry, then overlay new liner or support designs — validated in situ.

Structure Rehabilitation & Retrofitting
Scans of existing frames capture subtle deflections or misalignments. New modules fit gracefully, avoiding costly field rework.

Machinery Upgrades
Need to install a new motor, gearbox, or auxiliary module? Scanning ensures the new parts slot in perfectly without interfering with existing housing or supports.

Plant Layout & Flow Systems
3D context of the plant floor, piping, structural beams, clearances — all captured from scan and integrated into layout models so new designs respect real constraints.

Overcoming Common Challenges

Challenge	Our Approach
Noise, data clutter	Pre-filter scanning, segmentation, selective reconstruction
Missing geometry (occluded zones)	Use multiple scan angles, supplement with manual measurements
High complexity models	Simplify by feature priority, reference geometry, and parametrisation
Tolerance vs reality	Use best-fit surfaces and design with allowable tolerances rather than rigid conformity

Why This Matters (More Than Ever)

First-fit confidence: designs built to measured reality — fewer field surprises
Reduced risk & rework: clash detection, interference, assembly issues exposed early
Faster iteration & changes: model-driven variation, not red drawing
Lifecycle continuity: models evolve with the asset — rescan, revalidate, retrofit
Better collaboration: shared 3D models become the central reference across stakeholders

Hamilton By Design Advantage: Purpose, Scanning, Precision

At Hamilton By Design:

We don’t just convert scans to models — we engineer them with flexibility, annotations, and constraints.
Every model we deliver is ready for simulation, retrofit, or extension.
We build for future change — not just the version you order today.
Our pipeline bridges field work and digital domains — integrating site scanning, design modelling, and engineering validation.

We call that smart mechanical design with digital reality — where your CAD no longer guesses, but knows.

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3D CAD Modelling | 3D Scanning

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Parametric Solid Modeling

The Team at have extensive experience with 3D mechanical part design, , and assembly creation. Our mechanical designers are very familiar with the complicated and surfaces that are required for many types of products. Hamilton By Design CAD engineers excel in developing fully constrained components that are modelled in a wide range of materials offering a complete scope so that materials can meet a wide range of product design requirements.

Our design highly skilled engineers utilize the latest to create their mechanical designs. 3D outputs can be easily generated from the design process to allow our clients to get a good view of the mechanical design prior to the construction of any .

Our mechanical designers will create all of the manufacturing drawings and documentation to accompany the 3D CAD model. These drawings will include the detailed part drawings and the assembly drawings that will be required for the factory.

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Parametric Solid Modeling — Design Intelligence Meets Reality

At Hamilton By Design, our mechanical designers bring years of experience in 3D modelling, assemblies, and advanced geometry. But in 2025+, the frontier is not just parametric modelling — it's coupling that with 3D scanning to deliver designs grounded in real-world reality.

Parametric solid modelling gives us the flexibility, editability, and relationship-driven logic engineers need. Scanning gives us the spatial truth. Together, they create a design platform that is both intelligent and reliable.

Why Parametric Modelling Remains Core

Parametric modelling is about more than curves and solids. It’s about design intent.

Fully constrained components: Every part is built with defined dimensions, constraints, and relations so that changes can ripple predictably through the model.
Material flexibility: By defining material properties early, we can drive calculations, simulation, and value comparisons transparently.
Iterative design freedom: Change one parameter (thickness, radius, length), and the geometry updates coherently — no manual re-sketching.
Assembly behavior: Mates, constraints, and motion behavior become part of the model, not an add-on.

In short: parametric modelling turns geometry into a living system, not just a static drawing.

When you integrate parametric modelling into your mechanical workflow, the result is:

Less manual error
Faster iteration
Better reuse of design modules
Cleaner models that survive redesign cycles

But parametric modelling alone still assumes you know the environment. In retrofit or complex environments, that assumption often breaks down. That’s where 3D scanning saves you.

Elevating the Workflow: Parametric + 3D Scanning

Imagine this: you're tasked with adding a new equipment module or retrofit to an existing plant. You have only legacy drawings, partial CAD, and decades of structural creep. Where do you begin?

Here's how we proceed at Hamilton By Design:

3D Scan / LiDAR Capture
We bring portable laser scanners to your site — either static or while systems are live — to capture the physical world. The result: a high-density point cloud capturing every surface, offset, and distortion.
Point Cloud Processing & Cleaning
We register multiple scans, eliminate noise, filter redundant data, and segment surfaces relevant to your project — beams, existing structures, pipes, concrete slabs, equipment.
Feature Extraction & Reverse Modelling
Using the processed point cloud, we extract geometry: planar surfaces, curves, lofts, extrusions, arcs. That becomes the base reference for our parametric model.
Parametric Reconstruction
We rebuild the extracted geometry as editable parametric features — fully constrained, dimensioned, and relational. We embed design intent, constraints, and modular logic.
Integration, Assembly, and Validation
The new parts or subassemblies are designed in context — mated to scanned reference geometry. We run interference checks, motion/mate behavior, and situational simulation (e.g. clearance, deformation, alignment).
Simulation & Verification
Once the model is solid, we run FEA, modal, thermal or other relevant analyses to validate performance under real-world loads — now informed by the scanned geometry and correct spatial context.
Deliverables & Lifecycle Link
We deliver full 3D models, drawings, and scan references. The scan + model become the baseline for future updates, retrofits, or condition comparisons.

What This Enables in Mechanical Design

This integrated approach unlocks capabilities that older CAD-only workflows simply can’t match:

First-fit confidence: Because your design is built atop reality, surprises on site are rare.
Clash avoidance: You can detect spatial conflicts early — not after parts are fabricated.
Evolutionary design: Future changes, additions, or retrofits slot in cleanly because the reference geometry is accurate.
Digital twin readiness: The scan + model pairing yields a basis for digital twin, monitoring, comparison, and performance tracking.
Better stakeholder alignment: Visual 3D models overlaid on real surfaces ease review, approvals, and field validation.

Practical Use Cases

Equipment retrofit in existing structure
For instance, fitting a new gearbox, support frame, or structural bracket onto aged plant structure. Scanning gives the exact mounting points, offsets, and misalignment. Parametric modelling places the new parts precisely, eliminating guesswork or rework.
Wear replacement on rotating machinery
Over time, wear, thermal expansion, or deformation shift geometry. By scanning the actual component or liner, you rebuild the as-worn geometry, design replacement, and validate fit without surprises.
Plant layout and extension design
When extending a plant, adding conveyors or piping, you must design around existing beams, walls, and infrastructure. The scan + model strategy ensures that new modules respect real clearances, pipe runs, supports, and floor deviations.
Structural alignment and refurbishment
Aging structures bend, sag, or drift. Scans reveal those distortions, which become the basis for model alignment, repair planning, or reinforcement design — all in parametric space.

Overcoming Challenges in Scan-Model Workflows

Integrating scans and modelling isn’t trivial. Some challenges include:

Challenge	Strategy
Point-cloud noise and clutter	Filter aggressively, segment relevant surfaces, restrict modeling to key geometry.
Occluded zones or missing data	Use multiple scan angles; supplement with manual measurement to fill gaps.
Complex surfaces difficult to parametrize	Use hybrid modelling (free-form + parametric) or surface fitting techniques.
Tolerance mismatch between scanned and nominal geometry	Fit surfaces using best-fit algorithms; maintain tolerance bands.
Heavy scan data size	Use down sampling or region-of-interest clustering to manage scale.

The key is not to over model every detail — focus on the features that matter.

Why Hamilton By Design Adopts This Approach

We didn’t adopt scanning simply as a novelty — we did it because the combination of parametric modelling and scanning fundamentally improves quality, speed, and confidence in mechanical design work.

Reduced rework: Far fewer field adjustments, clash fixes, or misfits.
Greater accuracy: Designs reflect reality, not guesses.
Flexible updates: As-built changes, wear or modification can be rescanned and folded into living models.
Stronger client collaboration: Models grounded in site reality foster clarity in peer reviews, procurement, and fabrication.

In every project, we aim to deliver more than a drawing. We deliver a spatially coherent, parametric model that aligns precisely with the built world and adapts gracefully over time.