SolidWorks Designers Lean on LiDAR and 3D Scanning to Deliver Fit-First-Time Designs

“Fit first time, every time” isn’t a marketing line — it’s a hard requirement in modern engineering, fabrication, and construction.

Across industrial, construction, manufacturing, and infrastructure projects, the cost of getting it wrong is high. A fabricated frame that misses anchor bolts by 10 mm, a pipe spool that won’t align with an existing flange, or a platform that clashes with services can quickly turn a planned installation into reactive site work, re-fabrication, and schedule overruns.

For SolidWorks designers, most of these failures don’t come from poor CAD modelling. They come from poor inputs: outdated drawings, undocumented modifications, inconsistent datums, and site measurements taken under time or access constraints.

That’s why more design teams are leaning on LiDAR scanners and engineering-grade 3D scanning. Not for visualisation alone, but to capture measurable, reliable site truth that can be trusted during design, detailing, fabrication, and installation.

Hamilton By Design’s Melbourne scanning workflows demonstrate this clearly — scanning is treated as an engineering input, not a surveying afterthought, enabling SolidWorks models that install as intended the first time.

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Why Melbourne projects demand fit-first-time accuracy

Melbourne supports some of Australia’s most complex engineering environments:

• large-scale construction and commercial developments

• advanced manufacturing and precision fabrication

• industrial plant upgrades and brownfield retrofits

• transport, infrastructure, and services coordination

• tight access sites with dense service corridors

In these environments, assumptions compound quickly. Services are layered, structures evolve over time, and legacy assets rarely match original drawings. A SolidWorks model built on uncertain geometry may look correct on screen — but fail the moment steel hits site.

Hamilton By Design’s Melbourne scanning pages highlight a simple reality: design certainty starts with measurement certainty.

👉 3D Laser Scanning & Engineering Services – Melbourne
https://www.hamiltonbydesign.com.au/home/engineering-services/3d-laser-scanning/3d-laser-scanning-melbourne/

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The real problem: “as-builts” don’t stay as-built

Most engineers and fabricators have lived this scenario:

• the drawing says a beam is square — it’s not

• the pipe route has shifted over years of modifications

• cable trays and services were added without updates

• anchor bolts are not where the plan shows them

In brownfield and retrofit work, drawings often represent design intent, not installed reality.

LiDAR-based 3D scanning replaces assumption with fact. A point cloud captures the real geometry — not just key dimensions, but the spatial relationship between everything on site. When that data is collected and processed with engineering intent, it becomes a powerful foundation for SolidWorks-based design.

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What “engineering-grade” 3D scanning actually means

Not all scanning is suitable for design.

A visually impressive scan can still be dangerous if:

• registration accuracy isn’t controlled

• datums aren’t defined

• critical interfaces aren’t captured with enough density

• deliverables aren’t suited to CAD and fabrication workflows

Engineering-grade scanning focuses on what must be correct for the design to fit:

• tie-in points

• mounting faces

• clearances and envelopes

• access and maintenance zones

Hamilton By Design positions its Melbourne scanning services around this principle — scanning planned around design outcomes, not just data capture.

👉 3D Scanning Services in Melbourne
https://www.hamiltonbydesign.com.au/3d-scanning-melbourne-cbd/3d-engineering-in-melbourne/3d-scanning-services-in-melbourne/

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How SolidWorks designers use scan data in practice

1. Design-in-context (the biggest value driver)

With a point cloud loaded into the design environment, SolidWorks designers can model new components directly against the as-built site. This is particularly valuable for:

• platforms and walkways

• structural steel additions

• equipment skids and frames

• guards and safety structures

• supports and brackets

Instead of designing to an abstract drawing, designers work against real geometry — reducing clashes and misalignment.

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2. Clash avoidance before fabrication

Clashes rarely appear in isolation. A handrail that clashes with a cable tray may force changes to adjacent steel, services, and access paths. Each late discovery multiplies rework.

Scanning allows designers to:

• identify clashes early

• adjust layouts while changes are cheap

• coordinate across disciplines before steel is cut

Hamilton By Design’s Melbourne content consistently frames scanning as a coordination and risk-reduction tool — especially for complex construction and industrial sites.

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3. Reverse engineering worn or undocumented assets

Many Melbourne projects involve assets that have been operating for decades. Wear, corrosion, and undocumented modifications mean original drawings are unreliable.

Scan-driven reverse engineering allows designers to:

• capture true interfaces

• rebuild accurate CAD geometry

• design replacements that fit existing conditions

👉 Reverse Engineering 3D Scanning – Melbourne
https://www.hamiltonbydesign.com.au/home/engineering-services/3d-laser-scanning/3d-laser-scanning-melbourne/reverse-engineering-3d-scanning-melbourne/

This approach is especially valuable when OEM information is missing or lead times are impractical.

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4. Verification before installation

Even when a design is largely complete, scanning enables verification:

• do bolt patterns align?

• is there tool access for installation?

• will lifts and rotations clear surrounding structures?

Verification reduces last-minute surprises and supports confident sign-off before fabrication.

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Why fabricators care about scan-driven design

Fabricators feel the cost of poor information immediately.

When designs don’t fit:

• steel must be reworked

• site crews improvise fixes

• installation windows stretch

• safety risks increase

Scan-driven SolidWorks design helps fabricators by:

• improving first-pass fabrication success

• reducing site welding and modification

• increasing confidence in shop drawings

• shortening installation time

The result is fewer phone calls from site asking, “Can we just cut this?” — and more installs that proceed as planned.

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The “fit-first-time” workflow that actually works

To consistently deliver fit-first-time outcomes, scanning must be integrated into the engineering process:

Step 1 — Define critical interfaces
Identify what must align: flanges, anchors, bearing seats, access envelopes.

Step 2 — Scan for outcomes
Capture not just the object, but the surrounding context it interacts with.

Step 3 — Establish and document datums
All parties must work from the same coordinate system.

Step 4 — SolidWorks design-in-context
Model new components against verified geometry.

Step 5 — Detail for fabrication and installation
Design in adjustability where required and document tolerances clearly.

Step 6 — Verify before steel is cut
Final review against the point cloud to confirm interfaces and access.

This workflow removes reliance on luck and replaces it with repeatable engineering control.

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Why “good help” matters — and what it looks like

Getting good help isn’t about adding more people. It’s about bringing together:

• accurate measurement

• engineering judgement

• practical fabrication knowledge

An engineering-led scanning workflow supports this by:

• reducing site visits

• enabling remote collaboration using shared spatial data

• compressing design cycles

• improving communication between designers, fabricators, and installers

It allows teams to focus on design quality, not damage control.

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Melbourne scanning pages to link from this post (4 live links)

These four Hamilton By Design pages support the narrative above and reinforce Melbourne-focused authority:

1. 3D Laser Scanning Melbourne
   https://www.hamiltonbydesign.com.au/home/engineering-services/3d-laser-scanning/3d-laser-scanning-melbourne/

2. 3D Scanning Services in Melbourne
   https://www.hamiltonbydesign.com.au/3d-scanning-melbourne-cbd/3d-engineering-in-melbourne/3d-scanning-services-in-melbourne/

3. Reverse Engineering 3D Scanning Melbourne
   https://www.hamiltonbydesign.com.au/home/engineering-services/3d-laser-scanning/3d-laser-scanning-melbourne/reverse-engineering-3d-scanning-melbourne/

4. 3D Scanning Melbourne CBD
   https://www.hamiltonbydesign.com.au/home/3d-scanning-melbourne-cbd/

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Closing: fit-first-time is engineered, not hoped for

SolidWorks is a powerful design tool — but it can’t fix bad inputs.

When designers lean on LiDAR and engineering-grade 3D scanning, they replace assumption with certainty. The result is:

• fewer clashes

• fewer site fixes

• smoother installations

• better safety outcomes

Fit-first-time designs don’t happen by accident. They happen when measurement, engineering, and fabrication are aligned from the start.

If the goal is to get good help and make sure things fit first time every time, engineering-led 3D scanning is no longer optional — it’s foundational.

Central Coast Structural Drafting: Using 3D Scanning to Deliver Accurate, Build-Ready Steel

 Structural drafting plays a critical role in the success of construction, industrial, and infrastructure projects across the Central Coast. From steel platforms and frames to building upgrades and plant modifications, the quality of structural drafting directly impacts fabrication accuracy, installation efficiency, and on-site safety.

On the Central Coast, many projects are delivered in brownfield or retrofit environments, where existing structures have evolved over decades and documentation is often incomplete. This is where engineering-led 3D scanning has become a powerful tool — providing reliable as-built data that structural drafting can be confidently based on.

At Hamilton By Design, structural drafting on the Central Coast is underpinned by accurate 3D laser scanning, ensuring steel and structural elements fit first time, every time.

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Why Structural Drafting on the Central Coast Is Different

Central Coast projects frequently involve:

• upgrades to existing industrial facilities

• building extensions and refurbishments

• tight access constraints

• interaction between new steel and existing structures

Relying on outdated drawings or manual measurements in these environments introduces unnecessary risk. Even small dimensional errors can lead to:

• misaligned steelwork

• clashes with services or equipment

• site rework and delays

Structural drafting supported by 3D scanning removes this uncertainty by capturing what actually exists on site — not what drawings suggest exists.

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Engineering-Led 3D Scanning for Structural Drafting

Hamilton By Design approaches 3D scanning as part of the engineering and drafting workflow, not as a standalone surveying exercise.

High-accuracy laser scanning is used to:

• capture existing steel, concrete, and building geometry

• verify column positions, levels, and plumb

• locate penetrations, embeds, and interfaces

• provide reliable reference geometry for drafting

This data becomes the foundation for structural drafting that reflects real site conditions.

👉 Learn more about 3D scanning services on the Central Coast:
https://www.hamiltonbydesign.com.au/lidar-scanning-central-coast/

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From Point Cloud to Structural Drafting Models

Once site data is captured, the point cloud is interpreted by engineers and drafters who understand structural behaviour, constructability, and fabrication constraints.

Structural drafting is developed using:

• verified as-built geometry

• coordinated structural models

• clear interfaces between new and existing steel

This process ensures drawings are fabrication-ready, reducing RFIs and preventing clashes before steel reaches the workshop.

👉 Explore Hamilton By Design’s broader engineering-led drafting services:
https://www.hamiltonbydesign.com.au/home/engineering-services/

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Supporting Structural Steel Drafting with Accurate Site Data

One of the most common causes of steel rework is inaccurate assumptions about site conditions. On Central Coast projects, Hamilton By Design mitigates this risk by integrating 3D laser scanning directly into the drafting workflow.

This approach supports:

• steel frames and platforms

• mezzanines and access structures

• building strengthening works

• retrofit and brownfield upgrades

Drafting decisions are informed by real geometry, not estimates — improving both constructability and safety.

👉 Learn how 3D laser scanning supports accurate modelling and drafting:
https://www.hamiltonbydesign.com.au/home/engineering-services/3d-laser-scanning/

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Structural Drafting for Central Coast Projects

Hamilton By Design regularly supports Central Coast clients across industrial, commercial, and infrastructure sectors. Structural drafting services are tailored to local project conditions and often combine:

• site scanning

• structural modelling

• coordination with mechanical and services layouts

• fabrication-ready drawings

This integrated approach is particularly valuable where new steel must tie into existing buildings or plant structures.

👉 Learn more about engineering support across NSW and regional areas:
https://www.hamiltonbydesign.com.au/home/engineering-across-australia/

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Linking Structural Drafting with Mechanical & Building Services

Structural steel rarely stands alone. It supports mechanical equipment, pipework, conveyors, access platforms, and building services. By combining structural drafting, mechanical engineering, and scanning, Hamilton By Design ensures coordination across disciplines.

This reduces:

• clashes between steel and services

• late design changes

• installation conflicts on site

Structural drafting becomes part of a coordinated engineering solution — not an isolated deliverable.

👉 Explore mechanical and structural engineering capability:
https://www.hamiltonbydesign.com.au/mechanical-engineering/

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Why 3D Scanning Improves Structural Drafting Outcomes

Using 3D scanning as the basis for structural drafting delivers clear benefits:

• steel fits first time

• reduced fabrication rework

• improved installation sequencing

• safer site execution

• better documentation for future upgrades

For Central Coast projects, where access and downtime are often limited, these benefits translate directly into cost and schedule certainty.

👉 Start with Central Coast 3D scanning services here:
https://www.hamiltonbydesign.com.au/lidar-scanning-central-coast/

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Final Thoughts

Structural drafting is only as good as the information it’s based on. On the Central Coast, where many projects involve existing buildings and infrastructure, engineering-led 3D scanning provides the clarity needed to draft with confidence.

By combining accurate site capture with practical engineering judgement, Hamilton By Design delivers structural drafting that works in the real world — reducing risk, improving buildability, and supporting successful project outcomes.

Solidworks Structural Design Sydney

Soildworks Structural Design

Solidworks Structural Design Sydney: Soildworks Structural Design: 

SoildWorks Structural Design 

Hamilton By Design 

  www.hamiltonbydesign.com.au

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Solidworks Structural Design Sydney: Solidworks Materials Handing

Solidworks Structural Design Sydney

 SolidWorks large assembly management is something that is optimized over time or experience on large assemblies.

Solidworks Materials Handing

Hamilton By Design

 Experience the difference at Hamilton By Design

 The history of Cad Software for the drawing board to where we are today

Computer-aided design CAD is the use of computers or workstations to aid in the creation, modification, analysis, or optimization of a design. CAD software is used to increase the productivity of the designer, improve the quality of design, improve communications through documentation, and to create a database for manufacturing. CAD output is often in the form of electronic files for print, machining, or other manufacturing operations. The term CADD for Computer Aided Design and Drafting is also used.

Its use in designing electronic systems is known as electronic design automation EDA. In mechanical design it is known as mechanical design automation MDA or computer-aided drafting CAD, which includes the process of creating a technical drawing with the use of computer software.

 Cad Software available today include:

• Alibre Design
• AutoCAD
• Autodesk Inventor
• AxSTREAM
• BricsCAD
• CATIA
• Cobalt
• Fusion 360
• IntelliCAD
• IRONCAD
• KeyCreator
• MEDUSA
• MicroStation
• Modelur
• Onshape
• Promine
• PTC Creo
• PunchCAD
• Remo 3D
• Rhinoceros 3D
• Siemens NX
• SketchUp
• Solid Edge (Siemens)
• SolidWorks (Dassault Systèmes)
• SpaceClaim
• T-FLEX CAD
• TurboCAD

 

Freeware and open-source Software’s

• Blender
• BricsCAD Shape
• BRL-CAD
• FreeCAD
• LibreCAD
• OpenSCAD
• QCAD
• Salome
• SolveSpace
• Tinkercad

 

Software at Hamilton By Design

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Soildworks Structural Design

SoildWorks Structural Design - Hamilton By Design

 Large Assemblies with Solidworks

1.) Use the Large Assembly and Lightweight Modes for Assemblies/Drawings

Large assembly mode will automatically trigger some set of performance improving options based on a user defined component threshold. Lightweight components have improved opening, rebuild, and closing times. Primarily the graphical information and reference geometry are loaded into memory, but the features that define the part are not loaded into memory. These cannot be edited or shown in the feature manager design tree.

Resolved – Parts, Assemblies and Drawings: In resolved mode, all components are fully loaded in memory.

Quick view – Parts: It opens the part only for viewing. You can able to select the configuration, but not the display state. You can move, scale, or rotate the model, but you cannot make changes. If any changes needed means switch to edit mode by the right-click in the graphics area and select the Edit command.

Quick view – Drawings: It opens only a simplified representation of the drawing. For multi-sheet drawings, you can open one or more sheets in Quick view.

Lightweight – Assemblies, Drawings: Loads only a subset of model data into memory. The remaining model data loads on need basis. Opening in light weight mode improves the performance of assemblies and drawings.

Large Assembly Mode – Assemblies: It contains a collection of settings that improves the performance of large assemblies.

Large Design Review – Assemblies: It opens very large assemblies quickly, So whenever we need to open the entire assembly with all the components and measurements you do not need to open up the entire assembly through fully resolved mode.

Use SpeedPak - Available with assemblies in Resolved, Lightweight, or Large Assembly Mode While working with large, complex assemblies open a model using SpeedPak configurations to improve performance.

References - It shows a list of files which is referenced by the selected assembly or drawing. You can also edit the locations of the listed files. 

2.) Creating Sub-Assemblies

Splitting our top- level assemblies into multiple sub-assemblies and encourages design teams to divide and conquer. Sub-assemblies are smaller and less compare to work with the top-level assemblies. This will also minimize top level mates and features which leads to faster solving. Wherever possible, minimize the use of flexible assemblies unless necessary.

3.) In Context Features

This is one of the great way for creating a part within our assembly. An assembly with many in context features is going to experience slower performance.

4.) Use SpeedPak Configurations

Only the mating faces or bodies that are required are loaded into memory. In this example, there is only three surfaces. The other features will just show graphical information and that is not selectable. This kind of practice helps us to improve our large assembly performance.

5.) Make Simple Configurations of Parts and Assemblies

Performance evaluation helps and suggests some possibilities to work faster with assemblies.Small details of parts such as fillets and chamfers should be suppressed for a simplified model. Just be sure that we maintain our important features that are used for mating and boundary surfaces. When only the appearance will be affected, we can use display states instead of configurations. This can work great when we want to hide all our hardware components.

6.) Use Patterns

The pattern allows repeating the selected features in a particular direction or shape based on your component placement with pattern driven commands. You can save your time five times fast. Instead of mates, we can use patterns for rebuilding number of instances.

7.) Limit the use of Helical Sweeps and Threads

In our simple bolt example, Thread feature will consume 87% of our rebuild time. Revolve thread feature will also consume 75% of our rebuild time.

8.) Save Files to the Latest Version

When working with files from an earlier version of SOLIDWORKS, they often take longer time to open and rebuild. So, while working with these files, it is recommended to save to the latest version. Use Task Scheduler for converting to latest versions.

9) System Options and Document Properties

SOLIDWORKS contains various performance options to handle large assemblies even faster. There is an option called verification on rebuild, with this option SOLIDWORKS checks every new or modified feature against all existing faces. When this is turned off, new and modified features will be checked against adjacent surfaces.

           While handling Large Assemblies, ensure you have enabled the below options.

            In Assembly settings, Points to Remember

• Checkmark your system option > Assemblies > Do not rebuild when switching to assembly window.
• Checkmark your system option > Performances > Level of detail (Less)
• Checkmark your system option > Performances > automatically load components light weight.
• Checkmark your system option > Performances > No preview during open (faster)
• Set your system option > Performances >Rebuild assembly on load to “Prompt”.
• Checkmark your system option > External References > Allow multiple context for part when editing in assembly.
• Set your system option > External References documents to “Prompt”.
• Set your Document Properties > Image quality > Shaded and draft quality (Low) & Wireframe High quality HLR/HLV Resolution (Low) for faster performances.
• The performance options, under Document Properties image quality can have a large effect on our models. Higher quality images are going to take more time to process. When working with assemblies, the image quality can be set to a common resolution for each part by selecting “apply to all referenced part documents”.

10) Hardware and Software

            Ensure our system specifications meet SOLIDWORKS minimum requirements.
            Always keep system updated with suitable graphics card and system drivers.

If you have any questions feel free to contact Hamilton By Design

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Engineering | Drafting | Laser Scanning

Solidworks Structural Design Sydney: Structural Detailing

Solidworks Structural Design Sydney: Structural Detailing: 

Structural Detailing is the art of producing detailed drawings for steel fabricators / steel erectors so that fabrications go together first every time.

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Structural Drafting

Structural Drafting 

The team at Hamilton By Design offer a 1st class Structural Drafting service

Based in Sydney and on the NSW Central Coast, Hamilton By Design is a Parametric 3D Modelling Drafting / Drawing Office.

Our team provid a complete Structural Drafting service, from steel fabrication and erection drawings to cover each area of the Structural steelwork industry.

Using the latest versions of 3D Parametric Modelling tools our structural steel detailing Software supports our drawing office with the capability to produce a wide range of projects from small platforms and stairs to large multi-story office blocks, from which we can also provide a variety of material lists and electronic data suitable for related CNC machinery.

For Structural Drafting that goes together first time every time

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Engineering | Drafting | Laser Scanning