Importing FARO Point Clouds into SolidWorks for Engineering Drafting
Laser scanning is increasingly used in engineering projects where accurate information about existing infrastructure is required. In industries such as mining, manufacturing and industrial processing, engineers often need to capture the real geometry of plant infrastructure before beginning design work.
One of the common workflows we use involves capturing a FARO laser scan, processing the point cloud data, and then importing that data into SolidWorks to support engineering drafting and modelling.
This post outlines the workflow that has worked best for us so far.
Why Use Laser Scanning for Engineering Drafting
Traditional engineering drawings often do not reflect the current condition of industrial facilities. Over time equipment is modified, structures are altered and undocumented changes accumulate.
Laser scanning provides a reliable way to capture the actual geometry of an industrial plant. This digital representation allows engineers to develop accurate designs for plant upgrades, structural modifications and equipment installations.
More information about engineering-grade laser scanning can be found here:
https://www.hamiltonbydesign.com.au/home/engineering-services/3d-laser-scanning/
Typical Workflow: FARO Scan to SolidWorks
Our workflow typically follows these steps.
1. Capture the Scan
The first step is capturing the point cloud using a FARO laser scanner. Multiple scan positions are used to capture the full geometry of the plant area.
This may include:
conveyors
structural platforms
pipework
access walkways
equipment supports.
2. Register and Clean the Point Cloud
The raw scans are then processed using FARO software to align the individual scan positions and create a unified point cloud.
At this stage we typically:
register scans together
remove noise or irrelevant data
trim unnecessary regions of the scan.
Cleaning the point cloud significantly improves performance when importing the data into CAD software.
3. Export the Point Cloud
Once processed, the scan is exported into a format suitable for CAD workflows.
Common export formats include:
E57
RCP / RCS
PTS
LAS
The choice depends on the software tools being used in the modelling workflow.
4. Import the Point Cloud into SolidWorks
The point cloud can then be imported into SolidWorks using the ScanTo3D tools or compatible import workflows.
Some practical steps that have worked well include:
reducing point density before import
dividing large scans into smaller regions
isolating specific plant areas for modelling.
Large plant scans can contain hundreds of millions of points, so optimisation before importing can improve performance significantly.
Modelling from Point Clouds
Once the point cloud is available in SolidWorks, it is typically used as a reference for building parametric geometry rather than converting the cloud directly into mesh surfaces.
Typical modelling steps include:
extracting planes from structural surfaces
sketching profiles using point cloud references
modelling structural members and equipment supports
developing assemblies representing plant infrastructure.
This approach produces clean parametric models that are suitable for engineering drafting and fabrication drawings.
Practical Tips for Working with Large Point Clouds
Based on experience, several practices have proven helpful.
Reduce Point Density
Very dense point clouds can slow down CAD performance. Reducing density in areas that are not required can significantly improve usability.
Divide Large Scans into Regions
Breaking scans into smaller files allows engineers to work on specific plant areas without loading the entire dataset.
Use the Cloud as Reference Geometry
Rather than converting the point cloud directly into mesh surfaces, it is often better to use the cloud as a visual reference while creating parametric geometry.
This results in cleaner engineering models.
Engineering Drafting from Scan Data
Once parametric models are created, they can be used to produce detailed engineering drawings such as:
structural steel drawings
access platform layouts
conveyor modifications
equipment support structures.
This process allows engineers to develop accurate designs for brownfield plant upgrades where existing drawings may no longer reflect the current installation.
Open Discussion: What Workflow Works Best?
The workflow above has worked well for many of our projects involving industrial infrastructure and plant upgrades.
However, point cloud workflows are constantly evolving.
We are interested to hear how other engineers approach this problem.
Questions worth discussing include:
What point cloud formats work best for SolidWorks workflows?
Are there better ways to optimise large point clouds before import?
What software tools are people using to simplify scan data?
Sharing practical experience helps improve the overall workflow for engineers working with scan-based modelling.
Laser Scanning and Digital Engineering
Laser scanning continues to play an important role in engineering projects involving existing infrastructure. By combining point cloud data with CAD modelling and drafting tools, engineers can develop accurate designs for complex industrial environments.
To learn more about engineering-grade laser scanning services visit:
https://www.hamiltonbydesign.com.au/home/engineering-services/3d-laser-scanning/
