Dimensional measurement of hot heavy forgings is desirable to permit real-time process control, but usually it is inconvenient because of the difficulty in working with very hot workpieces. We present a new three dimensional (3D) measuring approach based on a two-dimensional laser range sensor (TLRS). First, the measurement system is obtained by assembling a TLRS, an axis of rotation, and a servo motor, which rotates the scan plane of the laser ranger sensor and lets the TLRS scan forgings in different planes. Therefore, the coordinates of forging surface points can be obtained in a sensor coordinate system (SCS). According to the transformation matrix between the SCS and measurement coordinate system (MCS), coordinates of points in different SCSs can be transferred into one fixed MCS. Hence the actual 3D models of hot heavy forgings can be reconstructed by using a triangulated irregular network and be optimized by employing improved Delaunay rules. Different parameters of forgings, such as lengths and diameters, can be measured based on the 3D model. The new method is verified by experiments in both the laboratory and the forging workshop. The experimental results indicate that it is much more practical and convenient for the real-time, onsite measurement of hot heavy forgings.