Mechanical Design: Smart Mechanical

Hamilton By Design offer first class mechanical design and detailing services in terms of quality furthermore over recent weeks Hamilton By design have invested in the latest developments in Smart Mechanical which operates on the SolidWorks platform. Smart Mechanical offers the most cost effective 3D modeling with parametric models.

For more information on Smart Mechanical that runs on the SolidWorks platform contact

www.hamiltonbydesign.com.au

Smart Mechanical | Mechanical Design | Solidworks Platform | Mechanical Detailing | Mechanical Drafting

Smart Mechanical Design: LiDAR, 3D Modelling & the Modern Engineering Platform

Mechanical engineering is no longer just about parts, drawings, and assemblies. The smartest, highest-performing designs today live at the intersection of data capture, parametric modelling, and simulation-backed validation.

At Hamilton By Design, we believe the future of mechanical design is built on a robust platform—one that integrates LiDAR scanning, 3D CAD modelling, and engineering intelligence.

This post reframes the “SolidWorks platform” idea into a broader vision: a mechanical design ecosystem driven by real-world data and engineered precision.

🔍 From SolidWorks Platform to “Reality-Linked Platform”

Originally, we described a “Smart Mechanical SolidWorks Platform” as the design environment where parts, assemblies, and drawings were linked in one parametric system. That’s still fundamental. But today, we overlay that platform with two critical dimensions:

LiDAR scanning to capture existing geometry physically
3D modelling that rebuilds that geometry in parametric form

Together, they create a reality-linked mechanical design platform — where your CAD is not just idealized design, but informed by measured truth.

🛰️ Where LiDAR Scanning Enters the Equation

Imagine you walk into a production plant with only legacy 2D prints or outdated CAD, and you need to design a new chute or structural module. How do you ensure what you design fits?

LiDAR scanning solves that.

We scan existing plant infrastructure in high-resolution — capturing every angle, weld, gap, and interference.
The scan becomes a point cloud: a dense map of the real-world surfaces.
We turn that point cloud into editable 3D geometry, which becomes the substrate for all further design.

This pipeline ensures your designs are physically grounded — no surprises when steel hits reality.

⚙️ Building the 3D Model Ecosystem

Once we have the scan-derived geometry, we integrate it into a parametric CAD platform (SolidWorks or equivalent). The process involves:

Tracing reference surfaces from scan to build sketches
Reconstructing profiles, lofts, and extrusions to match actual shapes
Defining constraints, mates, and motion paths in context with surroundings
Embedding metadata (material, tolerances, finish) consistent with original intent

Now your model is not a conceptual ideal — it’s a living representation of your asset environment, ready for simulation, fabrication, or retrofit.

🌡 Integration with Engineering Validation

A model driven by LiDAR and built with parametric logic is just one bridge. The next is engineering validation:

Static stress/FEM analysis on accurate geometry ensures the design meets strength requirements under real loads.
Modal or vibration analysis helps detect resonance conditions in the physical context.
Thermal expansion or distortion analysis ensures geometry fits when subject to thermal gradients in the real system.

Because the model reflects the actual built environment, these analyses are more precise and trustworthy.

🧠 Practical Applications at the Intersection

Here’s how we use this hybrid approach in real projects:

Chutes & Hoppers Retrofitting
Scans capture wear, distortion, and misalignment. 3D models allow precise liner shapes, mounting modifications, or reinforcement design — fit verified from the first fabrication run.
Conveyor Realignment
We scan footings, stringers, and drive trusses; model the full conveyor chain; adjust geometry to eliminate misalignment or belt tracking issues before any welds or bolts are placed.
Plant Expansion Projects
When adding new equipment, the scan-model platform shows exactly where new attachments will interfere with existing pipework, foundations, or structures — reducing costly clashes.
Machinery Refurbishment
You receive old machines without models or documentation. We scan them, reconstruct the framework in 3D, and deliver a working CAD dataset for maintenance, redesign, or spares fabrication.

📈 Why This Approach Delivers Tangible Value

Benefit	Engineering Outcome
First-time fit	Fewer surprises and field modifications
Reduced rework / scrap	Accurate geometry means less trial-fitting
Faster design cycles	Decisions made on concrete data, not assumptions
Better stakeholder clarity	Visual 3D models reduce miscommunication
Data continuity	Base models that evolve with your plant

And downstream, this data-rich platform enables digital twins, continuous monitoring, and better predictive maintenance workflows.

✅ How Hamilton By Design Implements It

Our typical workflow on a project looks like:

Site LiDAR scan — either static or active while plant runs
Point cloud processing — cleaning, registration, filtering
Feature extraction & modelling — turning surfaces into parametric CAD parts
Assembly & constraint setup — mates, interfaces, motion behavior
Simulation & validation — stress, vibration, thermal as needed
Client review & signoff — highlighting discrepancies and assumptions
Deliverables — CAD, annotated models, fabrication drawings, simulation reports

We keep geometry, analysis, and environment locked in sync. Future upgrades or changes are easier because the digital base reflects the real plant.

🧭 Positioning This for the Future

SolidWorks (or any parametric CAD) remains the backbone of the design platform. But without grounded data input (via LiDAR) and smart modelling, that backbone may break under uncertainty.

The future mechanical design platform is one where your models already know where walls, pipes, wear liners, and structural supports are — because they were scanned. Engineers then layer only what changes, rather than recreating everything from scratch every time.

In practice, this hybrid approach yields: