Small Shop Makes Big Gains with CAD/CAM Software
Stainless Fittings Group (SFG) is a mom-and-pop machine shop that, among other things, produces precision military antenna parts for an automaker supplying the U.S. Department of Defense.
The Challenge
Before 2015, CNC programming was done by hand using 2D paper drawings and customer notes.
The Solution
Introducing Mastercam® (the most widely used CNC software for CAD/CAM operations) streamlined the programming and manufacturing process resulting in higher quality parts and additional business from the DOD.
Benefits
- Using solid models from customers sped up production planning.
- Mastercam Mill enabled creation, verification, and optimization of toolpaths.
- Verify and Backplot were used to reduce setups and improve cycle times.
- Using Dynamic Motion led to shorter cycle times and extended tool life.
Project Details
Stainless Fittings Group (SFG) is a mom-and-pop machine shop located in Traveler’s Rest, SC that produces stainless steel military antenna parts for a supplier to the U.S. Department of Defense (DOD).
When Greg Williams, SFG’s CNC Supervisor, stepped in in 2015, parts were programmed by hand from 2D paper drawings provided by the customer. “I started here in 2015, but it was like stepping into the `80s,” explained Williams. “Everything was programmed by hand from a 2D paper drawing provided by the customer, and all of the fixtures were cobbled together-sometimes from old fixtures used for other parts. They got by with what they had.”
As a long-time machinist, CNC programmer, and user of Mastercam, Williams understood the potential of making the switch to CAD/CAM software.
With the introduction of Mastercam, SFG could accept solid models. This streamlined intake of new parts, as well as communication and production planning since everyone was looking at the same renderings. Making better parts faster is the goal of every manufacturer, but for small shops, efficiency is especially important. SFG runs the DOD parts on four mills and nine lathes. None of the lathes have live tooling, so being able to experiment with new toolpaths and operation strategies helped speed cycle times considerably by adjusting how much work could be done on the lathe before moving it to a mill to finish, or vice versa.
Mastercam Mill gives machinists the ability to create, verify and optimize machining strategies specific to the parts, machines and tools they are using, and then generate the CNC toolpaths they need to run the part.
Using Mastercam’s Dynamic Motion technology, programmers simplified fixturing to take full advantage of the fourth axis, going from producing 50 parts a day to more than 125. Mastercam’s Dynamic Motion gives users the ability to consider material properties, tool properties and machine properties to create toolpaths and motions that extend tool life and reduce cycle times, which in turn, extends the life and productivity of the machine.
Using Dynamic Motion along with Verify and Backplot let them see the entire machining process virtually, allowing them to experiment with different methods and toolpaths without wasting machine time or materials. In SFG’s case, the machinists were able to eliminate multiple set-ups, increase tool life and shorten cycle times significantly, all while improving part quality. Dynamic Roughing was used to switch to insert-type cutters for improved tool life and shorter cycle times.
While the software system has quickly become an essential tool in making better parts faster, one of the more unexpected things CAD/CAM software has become for SFG is a sales tool. Once Williams understood the new capabilities the software enabled for the company, he saw the potential to go back to the DOD’s suppliers and bid on additional parts. He went back to the customer and let them know that the company had invested in technology upgrades. He explained his background and abilities and asked to bid on more complex parts and win new business.
As he considers winding down his career, Williams points out that pushing his own boundaries was a big factor in advancing his career, and pushing SFG’s boundaries has been key to the company’s growth. He is now passing his knowledge and work ethic on to the next generation of machinists, and he’s sure to point out that he’s not going to teach them how to run parts. He’s going to teach them how to be the best CNC machinists they can be so they are ready for whatever is next for the company and themselves.
Quick Facts
- Product Used: Mastercam Mill, Mastercam Lathe, Dynamic, Verify, Backplot
- Industry: Aerospace & Defense
“I started here in 2015, but it was like stepping into the ‘80s. Everything was programmed by hand from paper drawings. I could see the potential for Mastercam right away.”
Greg Williams, CNC Supervisor, Stainless Fittings Group, Traveler’s Rest, SC
