3D Forensic Reconstruction in Industrial Accidents with Hydraulic Presses

Published on January 06, 2026 | Translated from Spanish
3D forensic reconstruction of a hydraulic press with a human avatar interacting, showing risk zones and motion simulations in an industrial environment.

3D Forensic Reconstruction in Industrial Accidents with Hydraulic Presses

When a severe industrial accident occurs, such as a worker trapped in heavy machinery, digital reconstruction becomes an essential tool for clarifying responsibilities. By applying a 3D forensic pipeline, the entire scene is digitized using technologies like Artec Leo to capture every component of the machine and its spatial arrangement. Then, with programs like SolidWorks or Inventor, a precise CAD model of the press is generated, while platforms like Siemens Jack or Unity recreate the operator's movements through an avatar with their real dimensions. This procedure helps discern whether the incident was caused by a mechanical failure, a human error, or safety design defects. 🔍

Evaluation through Ergonomic Simulation

Ergonomic simulation in environments like Siemens Jack or Unity reproduces the operator's actions moments before the accident, examining aspects such as their body posture, limb reach, and field of view. The three-dimensional avatar, built from the employee's real anthropometric measurements, interacts with the digital model of the hydraulic press to detect danger areas. This facilitates determining whether the controls, protections, or safety barriers were appropriate, or if there were elements obstructing visibility or mobility, leading to a human error. The fusion of 3D scanner data and CAD modeling ensures that the simulation faithfully represents the real circumstances of the incident.

Key Components of the Analysis:
  • Reproduction of the operator's movements and postures minutes before the incident
  • Evaluation of the visibility and accessibility of the machine controls
  • Identification of interferences or blind spots in the work area
3D technology reminds us that, although machines don't get distracted like humans, their design can have more gaps than Swiss cheese, especially in terms of workplace safety.

Determination of Causes and Preventive Measures

After thoroughly analyzing the simulation, experts can establish whether the root cause was a mechanical failure (such as malfunctioning hydraulic valves), a human factor (distraction or incorrect procedure), or a design defect (absence of guards or protections). This method not only resolves the immediate question about the accident's origin but also generates specific recommendations to optimize safety in similar equipment, preventing future incidents. The combination of 3D technologies makes the investigation more objective and thorough than traditional techniques.

Aspects Investigated in Cause Determination:
  • Verification of the mechanical and functional state of critical components
  • Analysis of the sequence of operations and possible deviations
  • Evaluation of the adequacy of existing protection systems

Impact on Future Industrial Safety

3D forensic reconstruction not only provides clarity on past accidents but also lays the foundation for proactive prevention. By integrating 3D scanning, CAD modeling, and ergonomic simulations, systemic vulnerabilities are identified that can be corrected in future designs and operational protocols. This methodology represents a significant advancement in workplace accident investigation, offering a detailed three-dimensional perspective that surpasses the limitations of traditional reports. The implementation of these technologies in industry promotes safer environments and reduces the likelihood of recurrence of serious accidents. 🛡️