Why Fabrication Projects Need Both Site Scanning and 3D Modelling
Why Fabrication Projects Need Both Site Scanning and 3D Modelling
Fabrication projects often begin with a practical challenge: a new component, structure or assembly must fit within an existing site.
The project may involve a platform around existing pipework, a replacement chute inside an operating plant, a machinery guard, an equipment support frame or a fabricated skid that must connect to existing services.
In these situations, a successful result requires more than a set of manual measurements. It also requires more than a standalone SolidWorks model.
Site scanning captures what is actually present, while 3D modelling defines what needs to be manufactured. When the two processes are combined, fabricators and project engineers can develop designs that are better coordinated with real site conditions.
The Problem with Designing from Incomplete Site Information
Many fabrication projects are developed using old drawings, hand measurements, photographs, sketches or assumptions about the existing installation.
The available drawings may not reflect previous modifications. Equipment may have moved, pipework may have been rerouted, structural members may have been added, or the original construction may differ from the drawings.
Manual measurements can also be difficult when a site contains:
congested pipework;
irregular steelwork;
machinery and equipment;
cable trays and services;
restricted access;
elevated structures;
complex connection points;
limited shutdown time.
When important dimensions are missed, the resulting SolidWorks model may look correct on screen but fail to match the actual site.
This can lead to:
fabricated components not fitting;
clashes with existing equipment or structure;
incorrect connection locations;
repeated site visits;
wasted materials;
workshop rework;
installation delays;
additional crane and labour costs;
shutdown overruns.
Site scanning helps reduce these risks by creating a detailed spatial record of the existing installation.
What Site Scanning Provides
Terrestrial 3D laser scanning uses LiDAR technology to record millions of measurement points across the visible site.
These measurement points form a point cloud that represents the shape and location of existing objects.
Depending on the project, the scan may capture:
structural steel;
machinery;
platforms and handrails;
floors and walls;
pipework;
ductwork;
cable trays;
equipment supports;
connection points;
access areas;
surrounding obstructions.
The point cloud provides more than several isolated dimensions. It creates a three-dimensional record of the wider project area.
This allows the designer to return to the captured information during the modelling process without repeatedly visiting the site to check individual measurements.
Why Site Scanning Alone Is Not Enough
A point cloud is a valuable record of the site, but it is not normally a complete fabrication design.
The point cloud shows the existing environment, but it does not automatically determine:
what should be fabricated;
which materials should be used;
how components should connect;
where fabrication splits should occur;
how the assembly will be installed;
whether bolts and welds can be accessed;
whether the design is practical to manufacture;
what information belongs on the fabrication drawings.
Engineering and design decisions are still required.
The relevant site geometry must be interpreted and converted into a practical CAD model that supports the fabrication process.
What SolidWorks Modelling Provides
SolidWorks can be used to convert site information into organised parts, assemblies and fabrication drawings.
The designer can model the existing geometry that directly affects the project and then develop the proposed assembly within that environment.
Typical SolidWorks applications include:
machinery guards;
equipment supports;
welded frames;
platforms;
stairs;
brackets;
chutes;
hoppers;
ductwork;
sheet-metal components;
fabricated skids;
replacement mechanical parts.
The SolidWorks model defines what must be manufactured. It provides controlled geometry that can be measured, reviewed, revised and documented.
Once the design has been approved, it can be used to produce:
general-arrangement drawings;
assembly drawings;
part drawings;
fabrication drawings;
sections and elevations;
bills of materials;
DXF cutting profiles;
STEP, SAT or Parasolid files;
native SolidWorks parts and assemblies.
Connecting the Point Cloud to the SolidWorks Model
The value of the workflow comes from using the site scan and SolidWorks model together.
The point cloud represents the existing site. The SolidWorks model represents the proposed fabricated solution.
By reviewing the proposed model against the scanned environment, the designer can check whether the new assembly is properly coordinated with the surrounding plant and structure.
This may identify problems such as:
a support frame clashing with existing pipework;
insufficient clearance behind a guard;
bolts that cannot be reached during installation;
a platform interfering with existing services;
incorrect equipment connection points;
restricted maintenance access;
insufficient space for lifting or positioning the assembly;
fabrication sections that are too large to move into place.
Finding these issues during the modelling stage is generally more efficient than discovering them after the component has already been manufactured.
A Typical Site-Scan-to-SolidWorks Workflow
1. Define the Project Requirement
The first stage is to understand what needs to be fabricated and how it will be used.
The project team should consider:
the purpose of the assembly;
the installation location;
critical connection points;
the required materials;
available drawings;
fabrication methods;
lifting requirements;
access constraints;
maintenance requirements;
the proposed installation sequence.
Defining the requirement before scanning helps ensure that the necessary site areas and interfaces are captured.
2. Complete the Site Scan
A laser scanner is positioned around the project area to record the existing installation from multiple locations.
The number of scan positions depends on the size, complexity and accessibility of the site.
Additional scan positions may be required where equipment, columns, pipework or structures block the scanner’s view.
Photographs may also be recorded to provide visual context for the point-cloud information.
3. Register the Point Cloud
The individual scans are combined into a coordinated point-cloud dataset.
This registration process brings the scan positions together so the captured site can be reviewed as one three-dimensional environment.
The processed point cloud may be exported in formats such as:
E57;
RCP;
RCS;
LAS;
XYZ.
The selected format will depend on the design and coordination software being used.
4. Identify the Relevant Geometry
Not every object in the point cloud needs to be converted into a detailed CAD model.
The designer identifies the site geometry that affects the fabrication project.
This may include:
support steelwork;
floor levels;
connection plates;
pipework near the proposed assembly;
equipment outlines;
access zones;
walls and columns;
handrails;
maintenance clearances.
A selective modelling approach keeps the SolidWorks assembly manageable while preserving the information needed for design coordination.
5. Develop the SolidWorks Model
The proposed assembly is designed around the verified site geometry.
SolidWorks parts and assemblies can be used to define the size, shape and relationship of the fabricated components.
SolidWorks Weldments may assist with frames, platforms, stairs and equipment supports.
SolidWorks Sheet Metal may assist with guards, covers, transitions, hoppers and fabricated sheet components.
The model can also include purchased components, fasteners and connection details where required.
6. Review Clashes and Installation Access
The proposed design is checked against the captured site environment.
The review should consider more than whether the finished assembly occupies the available space.
It should also consider:
how the assembly will enter the site;
where lifting equipment can be positioned;
whether individual sections can be handled safely;
whether bolts and welds can be accessed;
whether tools can reach the connection points;
whether equipment can still be maintained;
whether surrounding services remain accessible;
whether the assembly can be installed in the proposed sequence.
A component can fit within the final location and still be impossible to install. This is why installation planning is an important part of the modelling process.
7. Produce Fabrication Documentation
Once the design has been reviewed, the SolidWorks model can be converted into a fabrication drawing package.
Depending on the project, the drawings may include:
overall dimensions;
materials;
weld information;
plate thicknesses;
member sizes;
connection details;
hole locations;
part numbers;
assembly references;
bills of materials;
relevant notes;
installation references.
The drawings should communicate the approved design clearly to the workshop and installation teams.
8. Fabricate and Install
The fabricator receives a design based on verified site information rather than assumptions.
This improves the likelihood that the completed assembly will align with existing connection points and fit within the available space.
It can also reduce the need for field modifications, unplanned cutting, welding or re-drilling during installation.
Practical Applications
The combined site-scanning and SolidWorks-modelling workflow is particularly useful for brownfield and existing-site projects.
Machinery Guards
Existing machinery may include irregular shapes, access doors, controls, piping and moving components.
Site scanning helps record the surrounding environment, while SolidWorks can be used to design a guard that considers access, clearance and fabrication requirements.
Platforms and Access Structures
Platforms, stairs and access structures often need to fit around existing equipment, steelwork and services.
The point cloud helps identify the available space, while the SolidWorks model defines the fabricated structure and connection details.
Chutes and Hoppers
Replacement chutes and hoppers may need to connect to existing conveyors, transfer points, equipment or structural supports.
Scanning can capture the existing interfaces, while SolidWorks can be used to develop the replacement geometry and fabrication drawings.
Equipment Support Frames
Support frames may need to align with existing floors, foundations, machinery or connection plates.
Using verified site geometry helps reduce the risk of misaligned baseplates, supports or equipment interfaces.
Fabricated Skids
A fabricated skid may need to connect to existing pipework, electrical services, ductwork or structural supports.
Site scanning allows the surrounding connections and clearances to be reviewed before the skid is manufactured.
Reverse Engineering
Where original drawings are unavailable, damaged or outdated, scanning and measurement can support the creation of replacement component models.
SolidWorks can then be used to develop the part geometry and manufacturing documentation.
Tools That Support the Workflow
A site-scan-to-SolidWorks workflow may use several technologies.
FARO Focus S70
The FARO Focus S70 can be used to capture detailed three-dimensional site information around plant, equipment and structures.
FARO Orbis
The FARO Orbis can assist with mobile reality capture across accessible site areas.
FARO SCENE
FARO SCENE can be used to register, process, review and export the scan data.
Autodesk ReCap
Autodesk ReCap can prepare point-cloud formats such as RCP and RCS for use in CAD and model-coordination workflows.
SolidWorks
SolidWorks can be used to develop mechanical parts, fabricated assemblies, weldments, sheet-metal components and production drawings.
SolidWorks Simulation
Where required, SolidWorks Simulation may assist with the engineering assessment of stresses, deflections, loads and fabricated assemblies.
Navisworks
Navisworks may be used for broader model coordination and visual clash reviews where multiple design disciplines are involved.
The main advantage does not come from one software package alone. It comes from combining accurate site information, practical fabrication knowledge, engineering judgement and controlled 3D modelling.
The Role of Design Consultancy
Design consultancy connects the scanning and modelling stages.
A design consultant helps determine:
what needs to be captured;
which dimensions and interfaces are critical;
what level of modelling is appropriate;
how the assembly should be divided for fabrication;
how the design will be installed;
whether access and maintenance requirements have been considered;
what information the fabricator needs.
Without this design input, a detailed scan may contain more information than the project needs, while a technically accurate model may still overlook practical site and fabrication constraints.
The design consultancy process turns the captured information into a workable project solution.
Benefits for Sydney Fabrication Projects
Combining 3D laser scanning with SolidWorks modelling can provide several practical benefits for Sydney fabrication projects.
These include:
improved understanding of existing conditions;
reduced dependence on outdated drawings;
fewer manual measurement errors;
fewer return visits to site;
better coordination between designers and fabricators;
earlier identification of clashes;
improved installation planning;
clearer fabrication documentation;
reduced workshop rework;
improved confidence before manufacturing begins.
These benefits can be especially important where site access is restricted, shutdown periods are limited or installation labour is expensive.
Conclusion
Site scanning and 3D modelling perform different but connected roles.
Site scanning records what is actually present. SolidWorks modelling defines what must be manufactured. Design consultancy connects the two processes and turns the captured site information into a practical fabrication solution.
For existing-site and brownfield projects, this coordinated workflow can help reduce dimensional uncertainty, identify potential clashes and improve the likelihood that fabricated components will fit when they arrive on site.
Hamilton By Design provides 3D laser scanning, SolidWorks modelling and mechanical design support for fabrication projects throughout Sydney and surrounding industrial areas.
By combining real site data with practical engineering and fabrication knowledge, projects can move from existing conditions to fabrication-ready drawings with greater confidence.
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