Multiaxis Approaches Applied to Medical Automation Parts
Big Drum Precision Machining and Automation specializes in producing parts like robotic grippers for automated medical lab cells. Many of these parts are difficult – if not impossible – to machine in three axes. Mastercam Multiaxis directs Big Drum’s CNC unit to create repeatable, high-quality parts.
The Challenge
Machining high-tolerance components for medical automation cells, which often have hard-to-reach cuts and odd geometries.
The Solution
Mastercam, the most robust CAD/CAM software for machining applications.
Benefits
- Multiaxis solutions that automatically generate safe, efficient toolpaths for complicated parts.
- Unified Multiaxis toolpath that holds all the multiaxis approaches in one, easy-to-access location.
- Dynamic Motion technology to quickly and safely remove material.
- Stock Model’s three-dimensional, maneuverable models that keep track of every geometry throughout cutting.
- Advanced in-software simulation that detects problems before they occur.
- Vast network of Channel Partners with experts to train users and troubleshoot problems.
Project Details
Big Drum Precision Machining and Automation serves the medical automation industry, producing the components that make up automated medical lab cells. Its Matsuura MX-330 PC10 vertical multiaxis CNC unit is paired with Mastercam CAD/CAM software to turn out these complex parts.
With the addition of the two, the shop metamorphosized from one focusing mainly on 2D milling and basic lathe to one fully capable of taking on any 3D and multiaxis application. The unit has already markedly reduced labor, hand-working, and set-ups; it also promises to widen margins with each quarter.
To those parts that were previously machined using traditional 3-axis strategies, Manufacturing Engineer Brody Huk is excited to apply multiaxis techniques. “The way the software works, it’s easy to port my programs over from 3-axis and only tweak a couple things,” he said. The coding works quickly and simply, meaning Huk has more time to focus on more exciting parts: robotic components of automation cells, like robotic grippers.
A wing on the gripper is somewhat suspended in space by a very thin gusset. Take too much off around the gusset, and the part crumples. Take too little off, and the part loses its mobility and much of its function. To safely removed the exact required amount, Huk uses his software’s Dynamic Mill toolpaths.
Dynamic Motion technology, the parent group of tools to Dynamic Mill, consists of various stock-aware machining approaches designed to intelligently remove material. Dynamic toolpaths not only calculate the absolute best angle and speed and depth at which to engage the cutting tool, they also make instant adjustments to these calculations during machining.
During milling, this translates to the fastest, safest material removal possible. The Dynamic approach mills away that section of the block while it is supported and then returns to drill the precision holes. Then Huk creates a stock model within the toolpaths group.
The Stock Model feature creates a 3D, maneuverable virtual representation of the part for each stage of milling. As users progress, they need only apply new toolpaths to the remaining stock, drastically reducing wasted motion at the machine. Huk uses the succession of updated models to follow the machining process and to find the best approaches for removing the next batch of material.
The stock model keeps operations tied to a 3D model, and it makes it easy for Huk to apply consecutive Dynamic toolpaths in various reorientations and view planes. He prefers to use Dynamic toolpaths for their superior cut pattern, tool life, and—most importantly—repeatability. The last thing Huk wants is to have the part break apart at the last moment.
Big Drum continues to be a company strengthened by concerted internal growth and noticed for its outstanding external growth.
Quick Facts
- Product Used: Multiaxis, Mill 3D, Mill. Lathe
- Industry: Medical
“It’s awesome having this machine simulation suite built into Mastercam. As I’m buying tools, I can drop them directly into my CAM software and check for collisions and avoidances. It’s been extremely helpful in lessening the learning curve because, as our 5-axis jobs take off, our focus is going to be on reducing hand-working parts after machining and reducing setups. The software makes it easy to import programs over from 3-axis and just redo a couple of areas rather than start from scratch. I can have working code very quickly.”
Brody Huk, Manufacturing Engineer, Big Drum Precision Machining and Automation, Burlington, Canada
