Panoramic Inc. cuts lead times by 45 percent · After downloading a SolidCAM demo version and...

Application Report Panoramic Inc., USA 01/08

ProductiveSolidCAM gives packager the benefits of High-Speed Machining

Panoramic, Inc. began nearly 130 years ago as the Janesville Paper Box Company housed in a brick factory in the fields of southern Wisconsin, United States. Today, the com-pany occupies a modern 100,000 square-foot facility, but its output is far from boxy. Panoramic, Inc. now specializes in custom-designed clear plastic 3D packaging – from clamshells that display razors and cell phones to domes that show off bakery confections.

The company with roots in the past, however, is rapidly becoming a new player in the mar-ketplace. Panoramic, Inc.’s production has grown 20-25 percent in the last few years, attracting several new clients in the food industry. A good deal of the new success, according to Tooling Supervisor Jim Appel, is due to the modernization of its production.

Besides the purchase of faster CNC mold-tooling mills, the technological boost came through the choice of the right software. By adopting SolidWorks, Panoramic could take on more sophisticated 3D forms; with SolidCAM, an integrated CAM solution in SolidWorks which creates the machining process, Panoramic cut the entire project time in half.

“High-speed machining is what we’re doing now, compared to hard milling,” says Appel, “Before SolidCAM, it took much longer. SolidCAM has reduced our lead times by 45 to 50 percent, definitely.”

The Total Package

When Appel came to the Janesville facility a few years ago, custom packaging jobs were designed in AutoCAD’s Mechanical Desktop. “We had to convert the designs into a wire-frame model, then save it onto an earlier

version of Mechanical Desktop so it could be recognized by the CAM package we had at the time. It got to be quite tedious and time-consuming. When customers called up and wanted certain changes, we would have to go back in there and make the edits on Mechanical Desktop, and of course we would have to take that whole drawing through the CAM program again to re-pro-gram the machines.”

Panoramic’s new software system elimi-nates this cumbersome procedure from program to program. Because SolidCAM is seamlessly integrated within the mod-eling application, corrections to the 3D model also automatically update the CNC machine code. SolidCAM’s associativity to the SolidWorks design model ensures that the latest version of the design model is used to generate the machining data.

“Overall, it’s more of a user-friendly soft-ware than other CAM programs I’ve used,” says Appel, “You don’t have to jump all over the place to get a simple operation done. SolidCAM also has automatic feature-hole recognition, which is great for us, since we

Panoramic Inc. cuts lead times by 45 percent

Panoramic Inc. provides thermoform plastic packaging for cosmetics, food, cleaning sup-plies, and other consumer products.

SolidCAM+SolidWorks help them to cut the entire lead time by about 50%.

have to drill thousands of air-evacuation holes in some of our parts. Just by hitting a few buttons, it drills all the holes we need.”Previously, Appel worked with another CAM software especially made to work in tandem with SolidWorks called CAMWorks. “I wasn’t too fond of the way CAMWorks operated. It got to a point of frustration using CAMWorks, that I started calling it CAN’TWorks,” jokes Appel.

“The ease of use of SolidCAM beats CAMWorks hands down. The difference in technical support was also remarkable. With CAMWorks, anytime we had an issue, the support people would come out to the site, but then they’d leave. They’d say, ‘we’re not sure how this works. We’ll get back to you later.’ SolidCAM technical support fixes the problem right away, usually when I’m talking on the phone with them. SolidCAM is just a different kind of company.”

Thermoformal Demands

Besides automatic updating, easier com-mands and reliable support, the advantage that accounts for the tremendous strides in production volume lies in mold preparation. Panoramic produces packaging through thermoforming. Thousand-pound spools of plastic sheeting are unrolled on thermo-forming machines. The sheeting is heated and softened as it reaches a concave half-mold. A vacuum bends the plastic down and an assist plug -- the other convex side of the mold -- presses down to create the

plastic form. Other mechanical presses in the machine finish and trim the mold according to its final design.

While injection-mold tooling consists of the entire shape inside a block, a custom package mold in thermoforming requires up to 20 different one-sided configurations to be installed throughout the production machine. With SolidWorks and SolidCAM, Appel can easily create these 20 tooling shapes from the original solid model, instead of programming each one separately.

“We’re making three complete tooling sets – actually up to 20 configurations each – every week,” Appel reports. “We’re only run-ning one shift in the tool room. We do all the programming during the day, as well as the drilling operations. Towards the end of the day, we load the milling machine with up to eight parts, sometimes they are iden-tical parts, other times they can be eight completely different parts. We then send the programs to the mill and run the parts over-night. With SolidCam, we can utilize ‘lights out’ machining with no worries. That’s how much I trust SolidCAM. ”

Other automation within SolidCAM allows Appel to store standard templates of under-cuts – often-used decorative 3D patterns, ribbing, or emblems -- that are engraved into the tooling through the 5-axis CNC cutter. SolidCAM automatically adjusts the pat-tern so it perfectly conforms to the size and shape of the package.

“That’s another thing: we’re getting fin-ishes that are lot better as a result of using SolidCAM,” adds Appel. “We pride our-selves in making our customer’s products look as appealing as possible. Lately we’ve won over customers who had been using our competition for years, because they’re looking for something of higher quality. And we can give them something more -- and do

it faster.”Author:

Brett Duesing, Strategic Reach

Application Report Panoramic Inc., USA 01/08

© 2008 SolidCAM Ltd.. All rights reserved.All brand and trade names are property of their respective owners.

The Leaders in Integrated CAM

SolidCAMFounded in 1984 by its Managing director Dr. Emil Somekh, SolidCAM provides manufactur-ing customers with a full suite of CAM software modules for 2.5D and 3D Milling, High-Speed Machining, Multi-sided Indexial 4/5 axes Milling, Simultaneous 5 axes Milling, Turning, Turn-Mill up to 5-axes and WireEDM. SolidCAM has the Certified Gold-product status from SolidWorks and provides seamless, single-window integration and full associativity to the SolidWorks design model including parts, assemblies and configurations. SolidCAM has today more than 12,000 seats installed. The company has been on a very rapid growth path since it implemented the SolidWorks integration strategy with annual growth rates over 30%. SolidCAM is sold by a worldwide reseller network in 46 countries.

www.solidcam.com

Panoramic Inc.Based in Janesville, Wisconsin, Panoramic, Inc. provides thermoform plastic packaging for cos-metics, food, cleaning supplies, and other con-sumer products. Panoramic builds its reputation through reliability, supplying its customers with creative packaging designs, the highest quality output, on-time delivery and exceptional service. For more information on custom plastic packag-ing, please see www.panoramicinc.com

Application Report Grodås AS, Norway 01/10

Productive

Although the success of the company is mainly based on experience and handi-craft skills, the new business opportunities induced Grodås to invest heavily in automa-tion tools for their production. In the year 2000, the company invested in new, intel-ligent woodworking machines and in CAD/CAM software. The machines were sup-plied by the Italian manufacturer Paolino Bacci, and for the CAD software, the com-pany decided for the 3D design system SolidWorks. Håvard Haugen, the son of the founder and the current Manager of the company: “SolidWorks is easy-to-use, has superior 3D design capabilities and comes with more than 14 CAD interfaces, that enable us to important the geometrical data from the variety of our customers.”

At that time, Grodås also decided to install a CAM system, that is well-known in the fur-niture industry. This software is not inte-grated in SolidWorks, but can import most 3D file formats to generate toolpaths from 2,5-axis to 5-axis Milling. With increased competence and experience in the automa-tion of the furniture production, the com-pany began also to explore other manufac-turing opportunities and industries. They ranged from wooden stocks for biathlon rifles to complex molds for plastics injec-tion or polyurethane foaming. As a conse-

quence, Grodås had to design more sophis-ticated 3D models in SolidWorks. Here, the company realized an important bottleneck of its CAD/CAM process - the missing seam-less integration between CAD and CAM. The SolidWorks files had to be exported to the CAM system in order to generate the tool-paths, a time-consuming and not error-free process . Also, when the customers change the design model, the toolpaths had to be generated again, as there was no associ-atity between 3D model and CNC toolpath. In addition, the functionality of the CAM system was limited, so that creative solu-tions for milling were often time-consuming to CNC program.

Therefore Grodås elaborated a new con-cept for the design and manufacturing of complex molds and plugs. It was imperative that due to the complexity of the machined parts, the reduction of the CAM program-ming time was very important for the future success. Therefore Grodås looked for a new CAM solution, that is seamlessly inte-grated in SolidWorks, and finally decided to test SolidCAM. With the single-window integration of SolidCAM in SolidWorks, all machining operations are defined, calculated and verified without leaving the SolidWorks environment. All 2D and 3D geometries used for machining are fully associative to

the SolidWorks design model. In a single CAM-part, several SolidWorks configurations can be used to represent different manu-facturing steps of the workpiece. When the geometry used to define a machining oper-ation is changed in the SolidWorks design, SolidCAM enables the user to automati-cally synchronize all machining operations

Grodås Mønsterteknologi, the specialists in woodma-nufacturing, have been founded by Oddvin and Anne-Lise Haugen in the year 1983 in Hornindal, Norway. Hornindal is located at the east end of the Hornindalsvatn (Hornindal Water), the deepest lake (514 m) in Europe, and is part of the wonderful Nordfjord area. The com-pany started in the basement of the Haugen family with the production of carved dining room furniture in birch wood. Two years later, Grodås built its first factory at the outer aera of Hornindal and simultaneously invested in new woodmanufacturing equipment. At this point, the company also became a subcontractor for the Norwegian furniture industry, with production of chairs and visible woodwork for sofa side walls.

SolidCAM+SolidWorks increase efficiency in WoodmanufacturingNorwegian company Grodås Mønsterteknologi succeeds with an innovative manufacturing solution

5-axis machining center Bacci in action

Simulation of the Twin-Head Bacci machine with SolidCAM

CAM Programming of the Twin table Bacci machine with SolidCAM

with the updated geometry. The full asso-ciativity to the SolidWorks design model reduces errors when the model changes and facilitates the process where updates are received for models already machined.

After downloading a SolidCAM demo version and reading the SolidCAM tutorial, Håvard Haugen already started to generate his first CNC programs. Due to SolidCAM’s simple, descriptive and intuitive user interface, he could, to his great surprise, generate the G-Code for previously difficult jobs without any knowledge other then experience with the old CAM software. He also found out, that many of the toolpath strategies he

missed in the old CAM system are already implemented in SolidCAM. After Grodås tested SolidCAM over a weekend, the com-pany contacted ProNor, the SolidWorks and SolidCAM reseller in Norway, and finally purchased the SolidCAM software.

With the support of SolidCAM Scandinavia, the post processors for the 5-axis simul-taneous Bacci machines have then been developed and tested onsite. Håvard Haugen states: “The SolidCAM support specialists came over to our marvelous Hornindal lake to finish the post proces-sors and provide us with initial training. Meanwhile, we have used the combined solution SolidWorks+SolidCAM in produc-tion for more than a year and we see the benefits all the time. The integration with SolidWorks meant that our learning curve for the new CAM was very short. Within one or two weeks we were up and running, and doing very complex parts. The asso-ciativity between SolidWorks and SolidCAM is pretty significant in terms of increasing the speed of production. When you have to make a change to a design, you don’t have to reprogram the CAM.”

Grodås is meanwhile using SolidCAM for the CAM Programming of three 5-axis Bacci machines in twin table setup as well as in gantry setup. Thus the workforce of three machine operators/CNC programmers and five production workers can now effi-ciently perform a whole range of different jobs. Some are for product development and prototyping, but most of the jobs are for the machining of surfaces in wood, MDF, plastics, polyurethane and epoxy. The com-pany utilizes all SolidCAM milling strategies, from 3 and 4-axis, 5-axis indexial to 5-axis simultaneous. Most of the parts are now machined with strategies, that have been missing in the former CAM system. Håvard Haugen summarizes. “We have found the combined solution SolidWorks+SolidCAM excellent for our use, and the transition to this combination has given us confidence that we are technologically at the tip of the spearhead. With SolidCAM and our new machinery equipment we are armed to the teeth for both ordinary and complex tasks in the future”.

http://www.grodas.com



Application Report Grodås AS, Norway 01/2010

Finished Biathlon rifle

3D CAD model of a Biathlon rifle stock

Håvard Haugen, Owner of Grodås: “Today we are heavily armed with both experience and high technology”.

SolidCAMFounded in 1984 by its Managing Director Dr. Emil Somekh, SolidCAM provides manufac-turing customers with a full powerful suite of CAM software modules for 2.5D Milling, 3D Milling, High-Speed Machining, Multi-sided Indexial 4/5 axes Milling, Simultaneous 5 axes Milling, Turning, Turn-Mill up to 5-axes and Wire-EDM. SolidCAM is the leader in integrated CAM and provides the highest lev-el of CAD integration, with seamless, single-window integration and full associativity to the CAD model. The integration ensures the automatic update of tool paths for CAD revi-sions. SolidCAM has today more than 14,000 seats installed. The company has been on a very rapid growth path since it implemented its CAD integration strategy. SolidCAM is sold by a worldwide reseller network in 46 countries. www.solidcam.com

ProNorProNor AS, located close to Oslo airport, is one of Scandinavia´s largest resellers of integrated CAD/CAM systems. ProNor sells and supports the whole SolidWorks’ software suite, including 3D modeling, FEM analysis and document management. Through a continuous process, ProNor has expanded the main product range to include SolidCAM for intuitive and efficient CNC programming. In Norway, ProNor serves more than 400 industrial customers and a lot of educational institutes. www.pronor.com

Application Report Lambeck + Kersten, 11/09

Productive

The Harz region is a place for nature lovers and people looking for adven-ture. With a national park and geolog-

ical park, Brocken peak and Bode canyon, as well as the Karst caves, the northernmost low mountain range in Germany not only offers impressive encounters with nature, but also many outdoor activities, such as mountain biking, climbing or hiking. That makes it surprising to find a company here in the “Augustenhöhe” industrial area in Harzgerode which has specialized in the manufacturing of foaming molds.

The explanation is simple. “Mold manufac-turing has a long tradition in this region,” says Ulrich Lambeck, one of the two com-pany founders. Even back in the days of the former German Democratic Republic, pistons and pressure-die-cast parts were manufactured for the Eastern European countries. Furthermore, a foam part manu-facturer produced packaging parts, made of styrofoam in Harzgerode. The needed tool-making was managed by the other company founder, Jürgen Kersten. Till today, there are very well-trained toolmakers in this region; which is a major reason for production to

take place at this site, far away from the industrial urban centers. In addition to using CNC machines, part of the final machining still involves some handicraft work.

The molds are exclusively made of alu-minum and are used for the styrofoam and polypropylene foaming in a wide range of applications. Products made by the foaming technology include, for example, styrofoam chips and packaging material for electronic devices. Furthermore, the company produces molds for load carriers, which can accommodate entire car doors

Since its foundation in 1994, Lambeck + Kersten GmbH has been making molds for packaging, carriers and functional parts made of styrofoam and other plastics. While every mold is unique, customers still expect quick time-to-market, in addition to problem-solving capabilities and high quality. With the integrated process chain, consisting of SolidWorks, SolidCAM and various CNC machining centers, production of up to five foaming molds per month is now the standard.

Producing foaming molds faster with SolidWorks and SolidCAM

Integrated process chaIn - the wInnIng edge

The HSM module shortens the machining time considerably, especially for complex molds. HSM smooths the paths of both cut-ting moves and retracts wherever possible to maintain a continuous machine tool motion. The result is an efficient and gouge-free toolpath, that translates to increased surface quality, less wear on the cutter tools, and a longer life for the machine tools.

or other impact and/or scratch-sensitive parts, such as side-view mirrors. In addi-tion, there are molds for functional compo-nents, e.g. for sanitary engineering such as insulating elements for fittings and pumps or line distributors and insulating plates for house fronts, as well as shock absorbers. In these segments, the mold parts must exactly fulfill the functional requirements.

All molds, manufactured for foam parts pro-ducers such as Storopack, Fagerdala, Ohlro, Dieckhoff, Fapack, Illbruck Sanitärtechnik

and Primanit in Austria, are unique. They are usually manufactured once for a certain product and have to meet specific require-ments. Packaging molds must, for example, reliably protect the product during its entire trip from the production site to the end user, which is often around the globe. In addi-tion, packaging is increasingly becoming a success factor. Unattractive packaging can often make a top-quality product a shelf warmer, or products could become damaged due to low-quality packaging.

“An important criterion for the success of our company and one of our major strengths is the quick processing of orders,” empha-sizes Ulrich Lambeck. Depending on the complexity, not more than a week goes by from accepting an order to the delivery of the finished mold.

This fast delivery is mainly due to the inte-grated solution SolidWorks + SolidCAM, including various CNC machining centers. The process chain already begins with the direct import of the customer’s CAD data, includes the mold design as well as the order calculation and continues up to the generation of the optimized G-Code for the cutting of the mold parts.

Lambeck and Kersten realized how impor-tant a continuous integrated process chain is when, in 2004, shortly before the con-struction of a new production hall, 80 per-cent of the orders were cancelled because a portion of their customers started sending their orders to lower-wage countries. Thanks to quality, flexibility and reliable delivery times, which ultimately depend on the inte-grated process chain, they could quickly win back a large portion of the orders.

Today, 80 to 85 percent of the customers send their CAD data in formats like IGES, VDA-FS, Parasolid, Step, SAT, DXF and DWG, which can be directly imported very efficiently. SolidWorks offers around 20 import interfaces for the direct import of CAD data from external systems. “This way, we can directly take over the design data from all our customers very quickly. That saves a lot of time when calculating the quotation and eliminates sources of error,”

Ulrich Lambeck: „The various automatic foam-ing machines are no problem for us. With our machine park, we can produce tool sizes up to a clamping surface of 1800 x 1300 mm and up to a weight of 600 kg.”

Jürgen Kersten: „An important criterion for the success of our company and one of our major strengths is the quick processing of orders. Depending on the complexity, not more than a week goes by from accepting an order to the delivery of the finished mold”.

Enrico Reiprich, Manager of the SolidCAM branch office in Zella-Mehlis: „Lambeck + Kersten GmbH was one of our early customers in Germany, and since then has been following the powerful development of the SolidCAM software.”

SolidCAM, seamlessly integrated in SolidWorks, ensures efficient CNC programming of the individual mold parts and guarantees powerful machining with an extensive range of Milling strategies.


says production specialist Ulrich Lambeck. SolidWorks easily reads CAD files which were created with other systems, such as Inventor, SolidEdge, Pro/E or Unigraphics. There are also interfaces available for CATIA V4 and CATIA V5.

Ulrich Lambeck: “SolidWorks as 3D CAD system has been a very good choice. It is a well-engineered 3D CAD system and almost an industry standard. The SolidCAM soft-ware, seamlessly integrated in SolidWorks, ensures the efficient CNC programming of the individual mold parts and guarantees high-quality and fast manufacturing on our CNC milling machines, thanks to a variety of milling strategies.”

It wasn’t always like that, Lambeck remem-bers: “Before the introduction of the sys-tems installed today, we produced molds mainly based on drawings or patterns, which was a lot more time-consuming.” Since product life cycles are getting shorter and shorter and molds for new products are always being demanded, the company intro-duced relatively early CAD/CAM technology for mold manufacturing.

Ulrich Lambeck started working with the SolidCAM predecessor system CADtool/NCtool in 1991 and used it efficiently for 2.5D machining. Enrico Reiprich, Manager of the SolidCAM branch office in Zella-Mehlis: “Lambeck + Kersten GmbH was one of our early customers in Germany, and since then has been following the powerful development of the SolidCAM software.”

Whereby Lambeck emphasizes that “Enrico Reiprich has proven himself to be a rec-ognized CAM specialist for many years. If there’s a problem, usually one call is enough to fix it. Many questions can be solved via remote diagnostics.” Also in the case of SolidCAM for SolidWorks, introduced to the market in 2002, the company again was one of the first users in the country. One year later, a mold designer specialized in SolidWorks has been hired. Since 2006, two CAD/CAM specialists are constantly uti-lizing the combined solution SolidWorks + SolidCAM.

The company’s machine park consists of two vertical machining centers, Hurco BMC 64 and BMC 4020, as well as two CNC bed milling machines, Pegasus KNC-Q 1250 and a Sachmann ARAKOS 521, and also conventional milling, drilling and turning machines. “Especially for older CNC machines, SolidCAM’s HSM module can be used to improve the productivity with reduced air-cutting and smoothing arcs that maintain continuous tool motion”, explains Jürgen Kersten.

The HSM module offers unique machining and linking strategies for generating high-speed toolpaths. It smooths the paths of both cutting moves and retracts wherever possible to maintain a continuous machine tool motion – an essential requirement for maintaining higher feed rates and elimi-nating dwelling.

With SolidCAM’s HSM module, retracts to high Z-levels are kept to a minimum. Angled wherever possible, smoothed by

arcs, retracts do not go any higher than necessary – thus minimizing air-cutting and reducing machining time. The result of High-Speed Machining is an efficient, smooth, and gouge-free toolpath. This trans-lates to increased surface quality, less wear on the cutter tools, and a longer life for the machine tools.

“For large CNC programs needed to cut very complex molds, we can substantially improve our competitiveness with the

SolidCAMFounded in 1984 by its Managing Director Dr. Emil Somekh, SolidCAM provides manufac-turing customers with a full powerful suite of CAM software modules for 2.5D Milling, 3D Milling, High-Speed Machining, Multi-sided Indexial 4/5 axes Milling, Simultaneous 5 axes Milling, Turning, Turn-Mill up to 5-axes and Wire-EDM. SolidCAM is the leader in inte-grated CAM and provides the highest level of CAD integration, with seamless, single-win-dow integration and full associativity to the CAD model. The integration ensures the auto-matic update of tool paths for CAD revisions. SolidCAM powers up the user’s CAD system into the best integrated CAD/CAM solution. SolidCAM has today more than 14,000 seats installed. The company has been on a very rapid growth path since it implemented its CAD integration strategy. SolidCAM is sold by a worldwide reseller network in 46 countries. www.solidcam.com

For the machining of molds, Lambeck + Kersten rely on the vertical machin-ing centers from Hurco with the Hurco control Ultimax 4 and CNC bed mill-ing machines from Pegasus and Sachmann with TNC 415 and TNC 355 controllers from Heidenhain.

Even older NC machines benefit from the quality of NC programs gener-ated with SolidCAM. To fully utilize the machine capacities, Lambeck and Kersten also carry out commissioned milling work for made-to-order and small-batch production.


HSM module,” emphasizes Lambeck. The CNC programs are reliable and, in addi-tion, associative to the part geometry. For complex molds with tough requirements for surface quality, NC programming could quickly become a bottleneck in the manu-facturing process, if you do not utilize the power of an integrated CAD/CAM-system.

Ulrich Lambeck is optimistic about the fur-ther development of the company. Due to the ever shortening product life cycles, new foaming molds will constantly be needed. By offering a recognized high quality standard in its market segment, Lambeck+Kersten can compete successfully long-term against the competition from the low-wage countries.


Packaging parts must fit exactly along the contours of the product. This is the only way the product can be protected during prolonged transport. A precondition for an exact fit is that the foaming molds must be manufac-tured with high precision.

The machine run times can be shortened by 10 to 15 percent by using the SolidCAM HSM module

Foaming mold and finished packaging parts - packaging for every prod-uct consists of two separate foam parts. Since the mold has multiple cavities, it can in one shot manufacture several packagings.

Text and Photos: Klaus Hennecke [email protected]

www.solidcam.com

Every CAD/CAM process chain is always only

as strong as its weakest link. The trans-

formation of conceptual design ideas into

machining technologies is a potential weak

point. If multisided machining of parts in

a single set-up should become a key for

economic success, experienced machining

specialists and the superior software tools

are needed. With SolidWorks and SolidCAM

Neumag found a 3D CAD/CAM solution that

is both powerful and practical with future

potential.

Oerlikon Saurer Textile, a division of the Swiss-based Oerlikon corporation, is the world leader in full-service solutions in tex-tile machinery and brings together leading brands such as Allma, Barmag, Jinsheng, Neumag, Melco, Saurer Embroidery, Schlafhorst, Volkmann and Zinser. The machines, systems and services cover the complete range of textiles manufacturing (with natural and synthetic fibres) and the production of nonwovens.

For over 55 years Neumag has been involved with systems and equipment in the worldwide synthetic fibre and nonwovens industry and is viewed as the market and technology leader for plants and systems producing BCF carpet yarn and synthetic staple fibres. In nonwovens the branch of the Saurer GmbH is also the top supplier on the market, offering a one-stop shop of com-plete solutions for all essential processes in the production of nonwovens.

A lot of very precise, but rather complex components are required to build these systems, which are for the most part cus-tomized. The efficient machining of these parts is a core competence of Neumag Saurer, where 220 of the 415 employees in Neumuenster work. The manufacturing spectrum ranges from small parts weighing 50 grams up to 10 ton monster workpieces measuring up to 5 x 3 x 2 m³. In addition to steel and pipeline design, Neumag has a versatile and extensive CNC machine park for turning and rotary milling, milling in 3,

4 and 5 axes as well as cylindrical and flat grinding. In addition to in-house production, up to 30% of available production capacity is taken by external orders, making Neumag the place to go for the complete machining of large and heavy workpieces and welded parts such as wind mills, engines, genera-tors, gearboxes, chassis, etc.

Sometimes involving 200 to 300 dif-ferent machining operations, the scope of machining workpieces is so extensive that available centres would work round the clock

“ Low Viscosity Oil ” for the Process Chain

PRODUCTIVE

WWW.SOLIDCAM.COM

Neumag, Germany 06/07

The profitable use of state-of-the-art machining cen-tres requires a powerful CAM department.

Neumag relies on SolidCAM for NC programming: The scope of machining for some workpieces comprises 200 to 300 different machining operations in a single set-up. In addition to roughing and smoothing, there are also a lot of drilling and deep drilling opera-tions.

for a week with one clamping. In addition to the complexity of machining, the ambitious range of parts keeps Production Specialist Thorsten Nebbe on the go. “The NC pro-grams basically contain our historically developed machining know-how. This is a fundamental component for the market suc-cess of every company. We now have nearly 40,000 tested and optimized NC programs in our archive.” An impressive number!

And the question comes up, which CAD/CAM system can master this “diversity” in quantity, quality, time/schedule and is also flexible?

Neumag Saurer has relied on the SolidWorks 3D CAD system for about 5 years. Thorsten Nebbe began at Neumag just as the system was introduced. Armed with 15 years of experience in different NC programming systems it became his task to evaluate and introduce a suitable 3D CAM system, which he now supervises as a full-time job. “We looked at a variety of solutions. A press release then brought my attention to SolidCAM. The Nortec trade fair in Hamburg took place shortly after that. And there I had the first opportunity for a presentation.” It was so convincing that three SolidCAM licenses were ordered after a test installa-tion in May 2002.

Seven SolidWorks+SolidCAM seats are now installed at Neumag. Thorsten Nebbe: “A striking argument in favour of SolidCAM was of course the complete integration in SolidWorks. However, more important to us were the CAM features, the program-ming approach and, above all, the issue of postprocessors.”

Neumag has currently installed 24 different CNC centres, e.g. OKUMA, Hermle, Burkhardt + Weber, Mazak, Deckel Maho, SHW, being supplied with NC programs via a DNC net-work. The range of control units varies from diverse OKUMA OSPs and different genera-tions of Heidenhain and Siemens to the con-trol units of Mazak. Thorsten Nebbe: “When

investing in CAD/CAM the postprocessors are mostly the smallest items. However, they tip the scales for the success of milling and are somewhat like the lubricant for every process chain.”SolidCAM provides the ability to tune the postprocessors perfectly to the CNC machine controllers. This is why step by step Nebbe wrote perfectly custom-ized postprocessors for each machine and each control unit. “The individual modifica-tion of the SolidCAM postprocessors is easy to learn. We are thus flexible and indepen-dent from external support.”

Functionally, SolidCAM today meets all requirements that have practical relevance at Neumag – and that’s mostly 2.5D jobs in all variations. After 5 years of system maturation Nebbe in particular praised the “successful integration in SolidWorks and the practical approach towards NC program-ming. A CAM system should support pro-grammers in their method of working and not the other way around. Our NC programmers are experienced machinists.” To quickly tap the performance potential of the software, management treated each of the would-be CAM specialists to a solid SolidCAM training course. Nebbe can “strongly recommend to everyone” this investment, not for example, because the software is complicated, but because “the structured introduction con-veyed the philosophy of the software and a lot of tips and tricks.”

At Neumag every part and every order is dif-ferent. In order to have the optimal drilling or milling strategy, it’s not infrequent that up to 10 different home positions have to

For the automatic machining in one set-up the CNC machining centres require a variety of precisely preset tools that are immediately accessible.

Neumag has are currently 24 different CNC centres, like OKUMA, Hermle, Burkhardt + Weber, Mazak, Deckel Maho, SHW, all being supplied with NC programs via a DNC network. The range of control units includes diverse OKUMA OSPs, different generations of Heidenhain and Siemens control units and also control units from Mazak.

be defined in one part, especially when machining on 4 and 5-axis centres. This is why for Nebbe the “complete automa-tion for generating” recommended by some CAM vendors “is more of an impediment. Especially for the numerous 2.5D jobs, set-ting a machining strategy requires a lot of technological know-how and practical expe-rience. No matter if we have to machine alu-

minium, cast iron or high-temperature stain-less steels on 3, 4 or 5 axes, with SolidCAM we can incorporate our know-how and turn it into process-optimized NC programs.”

Nebbe appreciates the extensive simula-tion features of SolidCAM. “The possibili-ties are fantastic, but we try to simulate as little as possible and as often as needed.

As I said before, the NC programmers here are well-trained machining experts.” And the machine operators have to follow the direc-tions of the NC program when clamping a workpiece.

Things naturally look different for true 3D machining. Here, the faith in the mathematic algorithms and the reliablity of the CAM soft-ware is indispensable. According to Nebbe, SolidCAM is also a very good choice for 3D jobs, but such machining tasks are not the main issue at Neumag. Nethertheless the people in Neumünster appreciate to work in 3D. Options like zooming, rotating, color-izing, shading, showing and hiding details, etc. enable the NC programmer to work con-tinuously in a comfortable “What-you-see-is-what-you-get” environment. 3D helps the NC programmer to “understand” a complex workpiece in minutes rather than in days. “The integrated 3D CAD/CAM environment saves us a lot of time. You can, for example, create any cross-section and the dimensions are right there.”

Another advantage of the complete, Gold-cer-tified integration of SolidCAM in SolidWorks: CAD and CAM use the same 3D model with modifications to the part being automatically available for NC programming. Nebbe: “The CAD/CAM integration inside the program

Age is no barrier to CAD/CAM: Erwin Eipel has been building devices for 39 years. The Neumag vet-eran has been using SolidWorks+SolidCAM for more than 5 years.

Thorsten Nebbe, CAD/CAM specialist at Neumag in Neumünster: “With respect to the scope of work and the quality of the NC programs, SolidCAM can hold its own against significantly more expensive systems.”

Modern times: Neumag has a Flexible Manufacturing System which supplies the jobs to three model MA 800 and MS 600 OKUMA machining centres round the clock from a fully automated Fastems pallet warehousing system.

© 2007 SolidCAM Ltd.. All rights reserved.All brand and trade names are property of their respective owners. WWW.SOLIDCAM.COM

works smoothly and is also very efficiently implemented in the user interface.” For the processing of external orders it is a time and cost saving advantage, that SolidWorks is a true “CAD data omnivore”. There is hardly any CAD format that SolidWorks can’t import and process, where foreign CAD data can be immediately used for NC programming.

Thorsten Nebbe: “With respect to the range of applications and the quality of the NC pro-grams, SolidCAM can hold its own against significantly more expensive systems.” And the development is continuing rapidly. The new SolidCAM2007 R11 release pro-vides enhanced features like the support of additional tool types such as thread mills, reamers and copy mills, the new powerful high-speed machining (HSM) module for 3D milling, the new Rapid Verify simula-tion mode for fast solid simulation of 3D milling jobs and an accelerated NC program generation.

SolidCAM

Founded in 1984 by its Managing director Dr. Emil Somekh, SolidCAM provides manufacturing cus-tomers with a full suite of CAM software modules for 2.5D and 3D Milling, High-Speed Machining, Multi-sided Indexial 4/5 axes Milling, Simultaneous 5 axes Milling, Turning, Turn-Mill up to 5-axes and WireEDM. SolidCAM has the Certified Gold product status from SolidWorks and provides seamless, sin-gle-window integration and full associativity to the SolidWorks design model including parts, assem-blies and configurations. SolidCAM has today more

than 12,000 seats installed. SolidCAM has been on a very rapid growth path since it implemented the SolidWorks integration strategy with annual growth rates over 30%. SolidCAM is sold by a worldwide reseller network in 46 countries. The German speak-ing countries are supported by SolidCAM GmbH, located in Schramberg (Headquarter) and in 5 addi-tional offices

www.solidcam.com

Neumag, Germany 06/07

Idea

, con

cept

and

des

ign:

web

tem

ps.d

e

What you see, is what you get: Instead of CAM automatisms, the NC programmers at Neumag prefer to rely on their machining know-how

Oerlikon Neumag

For more than 55 years Oerlikon Neumag has been standing for strict customer orientation and long lasting reliable equipment in the worldwide synthetic fiber and Nonwoven industry. By open mindedness combined with the eager thirst for knowledge to fully understand the processes of its customers, Neumag became the market and tech-nology leader for complete turnkey lines for the production of BCF carpet yarns and synthetic sta-ple fibers. In the Nonwovenfield Oerlikon Neumag is the industry‘s first supplier for all major nonwo-ven processes. By bringing together the brands of Neumag, J&M, M&J, FOR, Autefa, Fehrer and Kortec, Neumag created a unique portfolio of key technologies. This enables the company to pro-vide turnkey airlaid, carding, and spunbond lines as well as innovative technological concepts for nonwoven products - all from one source.

http://www.neumag.oerlikontextile.com

Neumag is constantly enhancing and expand-ing the manufacturing capacities at the Neumünster location with state-of-the-art, high-performance 5-axis machining centres. In particular, the capacities for the complete machining of large and heavy workpieces in one set-up is also utilized by other companies.

In the world of motorsport; Alcon became a Technical Partner to the Honda F1 Racing Team by supplying brake callipers of a patented design. Alcon is also coopera-ting with other Formula 1 teams to develop the next generation of F1 braking systems. Alcon is well known in US motorsport, provi-ding brake components to the leading racing teams of the IRL and NASCAR series. In addition the motorsport departments within Audi, BMW, Ford, Honda, Peugeot, Renault and Volkswagen count on the technology of Alcon, as well as some prestigious road car manufacturers; including Brabus, Jaguar, Land Rover and Prodrive.

Alcon employs over 80 staff at its headquar-ters and manufacturing facility in Tamworth, located in the English West Midlands region. The international presence is ensured by further sales personnel in the United States and France. According to the requirements of the automotive industry, Alcon is certified to internationally recognised ISO TS16949 Quality Standard.

Alcon’s customers are making high demands on their suppliers. They demand not only highest precision and machining quality, but also manufacturing flexibility and short response times. This is the key to Alcon’s success. At the headquarters in Tamworth; many of the production functions are under one roof to maintain maximum control over quality and scheduling - an essential aspect

to the ‘rapid response’ approach. The abi-lity to machine, finish, assemble and test components in-house is often crucial to meeting customer deadlines.

Allan Ford, Senior Production Engineer with 15 years service at Alcon is one of the “veterans” in the company: “In the last 15 years, I have seen the company grow from 8 to more than 80 employees. Bottom-line; the reason for our success is our flexibility to convert design ideas into metal as fast as possible.” Alcon engineers are equipped with state-of-the art CAD/CAM software and profits are constantly being reinvested in capital equipment, including new CNC machining centres, computer controlled ins-pection equipment, and specialist tooling systems.

Alcon’s engineers are always in tight coope-ration with its customers. They take their ideas and complete the design through the manufacturing process. This requires a 3D CAD system, which can easily import the dif-ferent CAD formats of the customers and has powerful 3D modelling capabilities to modify and create the geometry. For several years, Alcon has been using the SolidWorks 3D system for design, and the Engineering

High Performance Manufacturing for High Performance Car ComponentsThe town of Tamworth, Staffordshire; is

not only known for its historic merits; but

also for its engineering and manufacturing

industry. Here the engineer and sports car

racer John Moore founded in 1984 Alcon

Components Limited. The company has

gained a worldwide reputation for manufac-

turing and supplying high specification brake

components and clutches to motorsport and

for high performance road vehicles.

PRODUCTIVE

WWW.SOLIDCAM.COM

Alcon Components Ltd., UK 03/08

3D model of a brake calliper, designed with SolidWorks

Applying High-Speed Machining to a calliper part results in excellent surfaces.

NC-Programming of a brake calliper with SolidCAM

© 2008 SolidCAM Ltd.. All rights reserved.All brand and trade names are property of their respective owners. WWW.SOLIDCAM.COM

department is equipped with 6 seats. Allan Ford: “For us, SolidWorks is a versatile soft-ware tool to accelerate our design process. E.g. in Formula 1, weight is always an issue. We are permanently investigating the reduc-tion of weight while maintaining the stabi-lity. For this, we need an easy-to-use and powerful CAD system, which also supports integrated analysis tools. Moreover, we use SolidWorks in the manufacturing department to design fixtures for locating and clamping the workpieces on the machine tools”.

To convert the SolidWorks design files to machined parts; Alcon uses CAM software which generates the G-Code for the CNC-machines. Bob Luck, who joined Alcon as CAD/CAM system manager in the begin-ning of the year 2004, states: “We analyzed our CAD/CAM process chain for a couple of months and found some weaknesses in our CAM system. As it had not been integ-rated into SolidWorks, it was sometimes not easy to get the design data quickly enough and error-free into CAM. Furthermore, we had to wait about 6 months to get a sui-table post processor from our CAM supplier, so that our Moriseiki CNC machine could run efficiently.” To optimize the overall pro-cess, Alcon finally decided to look for a new CAM system. Based on the experience with the old CAM system, 4 main criteria for the selection of the new software were defined: 1.) Seamless integration in SolidWorks, 2.) Broad range of CAM functionality, 3.) Powerful post processor capabilities and 4.) Excellent UK support.

After selecting 3 different CAM systems for the short list; each of the CAM systems had been installed in the Tamworth head-quarters for one month. During this period, Alcon had the chance to test all systems under real working conditions. Bob Luck: ” Our approach gave us the opportunity, not only to test the software functionality, but also the underlying support organization. For us, an excellent local support is abso-lutely vital.” Finally, Alcon decided to select SolidCAM as the new CAM solution. The company purchased two seats of the com-bined solution “SolidWorks+SolidCAM” for their manufacturing department. Bob Luck continues: ” We found out, that SolidCAM reduced our NC programming time by half. Also, we have been pleased with the ease-of- use and power of the 2.5D Machining module. A major criteria for us has been the UK support. Marks Stocks; the Technical Director of SolidCAM UK, helped us a lot in implementing the SolidCAM software in our shop floor, also by customizing the post processors perfectly to our machine tools. “Gordon Drysdale, Managing Director of SolidCAM UK adds: “Manufacturing auto-mation is a solution business and has to do a lot with competence and know-how. We at SolidCAM UK provide our customers not only with powerful automation software, but also with all the services including training, post processor development, project sup-port, consulting and systems integration. This helps them to meet their cost and time targets in parts manufacturing.”

SolidCAM has been used now extensi-vely since 2005 at Alcon. Recently, a new 5-axis CNC machine from Hermle has been installed, and SolidCAM’s 5-axis simulta-neous milling module is used simulate and program the machining process. Besides all the positive experience with SolidCAM,

Alcon has still some wishes. Bob Luck:” We are currently working on the machining of a newly developed calliper with many com-plex surfaces. We want to apply the Solid Verify module on it, and we need to speed up this process.” Like all relationship’s this is very much a “work-in-progress”, SolidCAM have always worked closely and listened to their customers requirements who in turn have to meet the demands of their custo-mers to develop tools for the shop floor that deliver.

About SolidCAM UK Ltd.

SolidCAM UK was formed in January 2002 by the current directors to sell and sup-port SolidCAM in the United Kingdom and Ireland. Since then, SolidCAM has been on a rapid growth path with annual growth rates more than 30%. SolidCAM UK is based in Barnsley, South Yorkshire, where a fully equipped training facility can be found for training and support purposes. All the people at SolidCAM UK are from engineering backgrounds, essential for the smooth ope-ration, knowledge of the customer’s require-ments and levels of support.

Allan Ford (left) and Bob Luck (right) introduced state-of-the-art manufactur-ing technology at Alcon Components Ltd., including a Hermle C20 5-axis machine and SolidWorks+SolidCAM as CAD/CAM “

Gordon Drysdale, Managing Director of SolidCAM UK: “We provide our customers not only with powerful manufacturing automa-tion software, but also with all kind of CAM services.”

Mark Stocks (SolidCAM UK) supported Alcon to customize the post processors for the CNC machine tools.

Alcon Components Ltd., UK 03/08

SolidCAM UK Ltd.

Unit 25 BBIC Innovation Way, Wilthorpe S75 1JL Barnsley South, Yorkshire United Kingdom

Phone: 44-1226-241744 Fax: 44-870-1126338

E-Mail: [email protected]

Application Report Basar Makina, Turkey 04/08

ProductiveThe Turkish company BASAR MAKINA has been founded in the year 1961 in Beylikduzu, Istanbul (Turkey) by Yasar Basar. The company started with the manu-facturing of machine equipment for the food and textile industry. Later this business has been extended to the manufacturing of com-plete production lines. BASAR MAKINA has built many of the tea factories at the Black sea side of Turkey.

Due to the increasing demands of the plastic industry in Turkey, the company started to supply also equipment for plastic pipe production lines. These pipes, made of Polyethylene, are used for example for waste water conduits. BASAR MAKINA, which is now managed by Yasar Basar´s son Cemal, not only became a well-known supplier of extrusion dies for plastic pipe manufac-turing, but meanwhile also manufactures complete production lines for specialized plastic pipes.

In the first years, design work had been done manually, which needed often weeks and months to finish. With the introduc-tion of the CAD technology, BASAR MAKINA speeded up the process by utilizing the 2D CAD system AutoCAD, which became a well accepted solution for a couple of years.

However with the increasing complexity of the products, BASAR MAKINA took the next step by migrating from the 2D CAD system to an integrated 3D CAD/CAM system. After evaluating several systems, the design and manufacturing team finally decided for the combined solution SolidWorks+SolidCAM. The ease-of-use, power and seamless single-window integration of CAD and CAM con-vinced the whole team: “With SolidWorks, we have a mainstream CAD platform that enables us to design complex extrusion dies efficiently. SolidCAM is seamlessly inte-grated in SolidWorks so that our program-mers can operate in the same window. In case we have to modify the design, we can update our CNC programs automatically”.

In the year 2005, the first seats of SolidWorks+SolidCAM have been installed. Very soon, the CNC operators could generate the G-Code for the JOHNFORD SC-41 CNC Milling center. Serhat Altintas from BASAR MAKINA states: “The most important point of SolidCAM is the ease-of-use: due to the single-window integration, a CAD user with no previous CAM experience can generate the G-Code in a very short time. We had no experience in CAM software before, but after 3 days training, we were able to manufac-ture all our parts without any problem using SolidCAM.”

For BASAR MAKINA, the associativity between the 3D design model and the corre-sponding toolpaths is a key element. When the geometry of the 3D design is modified, SolidCAM enables the user to automati-cally synchronize all machining operations with the updated geometry. Safak Kodaman, CNC Operator at BASAR MAKINA, concludes: “The associativity is an important time saving factor, as we modify our parts rela-tively often. The time we save is our most relevant competitive advantage. Due to the power of SolidWorks in 3D design and short

RACING AGAINST TIME

3D design model of an extrusion die in SolidWorks

NC-Programming of an extrusion die with SolidCAM

SolidVerify simulation with SolidCAM

programming time of SolidCAM, most of the manufacturing work, which took weeks in the past can now be finished in 3-4 days... We really love SolidCAM and our decision to select SolidWorks+SolidCAM has been the right choice.”

The SolidWorks+SolidCAM solution has been supplied to BASAR MAKINA by the Turkish reseller Tekyaz, located in Istanbul. Ahmet B.KULDASLI, SolidCAM product Manager of Tekyaz, summarizes: “The manufacturing industry in Turkey today is booming. This

generates demand for leading-edge, inte-grated CAD/CAM solutions like SolidWorks+ SolidCAM, provided by Tekyaz. However we not only provide manufacturing software but also support our customers by pro-viding training, post processor customiza-tion and other professional services. BASAR MAKINA´s success is also the result of the excellent cooperation between the customer and the solution provider.”

Application Report Basar Makina, Turkey 04/08



Ahmet B.KULDASLI, SolidCAM Product man-ager of Tekyaz

The final products: Polyethylene pipes

Finished extrusion die out of brass material

SolidCAM

Founded in 1984 by its Managing director Dr. Emil Somekh, SolidCAM provides manufactur-ing customers with a full suite of CAM software modules for 2.5D and 3D Milling, High-Speed Machining, Multi-sided Indexial 4/5 axes Milling, Simultaneous 5 axes Milling, Turning, Turn-Mill up to 5-axes and WireEDM. SolidCAM has the Certified Gold-product status from SolidWorks and provides seamless, single-window integration and full associativity to the SolidWorks design model including parts, assemblies and configurations. SolidCAM has today more than 12,000 seats installed. The company has been on a very rapid growth path since it implemented the SolidWorks integration strategy with annual growth rates over 30%. SolidCAM is sold by a worldwide reseller network in 46 countries.

www.solidcam.com

TEKYAZ (Teknolojik Yazilimlar ve Makine Tic. A.S.)

Teknolojik Yazilimlar (“TEKYAZ”) is authorized reseller of SolidWorks, SolidCAM and Moldflow software in Turkey. TEKYAZ is the leader in manufacturing software with nearly 30 employees and more than 15 years experience in the industry. The company´s main office is located in Istanbul and it has 4 additional branch offices in Ankara, Izmir, Bursa and Konya. In addition, Tekyaz has sales partners in Izmir, Adana and Kayseri. TEKYAZ provides different levels of training and support for its industrial and educational customers in the Istanbul headquarters.

“Teknolojik Yazimlar ve Makine Tic. A.S.” has been founded in 2007 as a dedicated CAD/CAM/CAE solution provider as a spin-off UMTAS A.S.. In the years before (1996 – 2006), the team of TEKYAZ formed the CAD/CAM/CAE department of UMTAS, supplying design and manufacturing software and related services to the Turkish industry. By offering training in state-of-the-art equipped classrooms, TEKYAZ contributes directly to shorter lead times and increased efficiency in production.

www.tekyaz.com

Big Bear Plastic Products Ltd, UK 02/08

Productive

Vacuum forming specialist Big Bear Plastic Products Ltd, based in Droitwich, UK has achieved an enviable position, supplying to a diverse range of markets from Leisure to Aerospace.

The company is able to offer consultancy and design services along with manufacture and supply, assisting customers from con-cept to components including tooling and material selection, while not forgetting the incorporation of customer specific supply chain requirements.

The company’s growth rate, coupled with the target of reducing project lead times, led Big Bear to invest in a CAM system that integrates with its current CAD solution - SolidWorks from Cadtek. The integrated SolidWorks+SolidCAM solution enables Big Bear to accept, manipulate and manufac-ture solid models, imported directly from its customers.

As component tolerances reduce and the pace of new tooling release and the need to link the validity of mould tooling, trim tooling and cutter path geometry increases, the use of an integrated CAD/CAM system gains importance. Being able to use cus-tomer generated model files to produce both tooling and cutter programs, has sig-nificantly improved project lead times.

Dan Patrick, Project engineer said, “It may still be necessary to manually program some components, which may not have valid model files,at the machine but with most new projects the model file is the heart of

the project, and it would be wrong not to use this as the source data at every oppor-tunitiy.” With advice from Cadtek, Big Bear Plastic Products Ltd installed two seats of SolidCAM, which integrate seamlessly with its SolidWorks CAD systems. Operating from inside SolidWorks, SolidCAM works directly with the model data, enabling the engineers at Big Bear Plastic Products Ltd to quickly add the 5-axis trimming paths once the datum and orientation of the part has been established. Dan Patrick added, “It isn’t uncommon for new components to come in families, so we start by program-ming the most complex one, which contains the most features. We can then simply sup-press some of the operations to get the trimming paths for the remaining simpler components.” Once the toolpath has been prepared, SolidCAM verifies it, showing the tool, the holder and the machine tool, picking up any collisions in its graphical sim-ulator and ensuring that the machine oper-ates safely and reliably.

SolidCAM trims 5-axis parts at Big Bear Plastic Products Ltd

SolidCAM not only generates the NC toolpaths, but also verifies them and simulates them including holder and machine tool.

Panels being trimmed at Big Bear Plastic Products

SolidCAM is easy to use, as it is “Single win-dow” integrated in SolidWorks

The programming work load at Big Bear Plastic Products Ltd increased rapidly during 2007; as its engineers were becoming familiar with the software, support spe-cialists from SolidCAM helped by creating some of the toolpaths. Dan Patrick said, “Assistance from SolidCAM helped us to overcome the initial backlog of work. Now that we have become more familiar, we regu-larly produce new trimming programs in less than half the time it would have previously taken.”

Programming ‘off line’ in SolidCAM has also raised the efficiency of the physical trimming equipment. Parts programmed manually on the machine resulted in downtime, as trim-ming could not continue at the same time. While parts are programmed in SolidCAM the machine can run without interruption.

Big Bear’s customers have seen benefits from the introduction of SolidCAM. Most cus-tomers now supply designs as CAD models, simplifying the transfer of data and ensuring that design intent is communicated unam-biguously. Within Big Bear Plastic Products Ltd, more and more parts go through the SolidCAM route, eliminating the possibility of error and enabling the company to offer project turnaround times which would previ-ously have been very difficult to achieve.

Dan Patrick concluded, “Growth at the com-pany is continuing at a very healthy rate with an emphasis on lean manufacture. The introduction of SolidCAM has contrib-uted to this expansion, enabling the com-pany to manufacture more complex parts in a shorter lead time, raising throughput, and maximising the productivity of our trimming machines.”

Big Bear Plastic Products Ltd, UK 02/08



SolidCAMFounded in 1984 by its Managing director Dr. Emil Somekh, SolidCAM provides manufactu-ring customers with a full suite of CAM software modules for 2.5D and 3D Milling, High-Speed Machining, Multi-sided Indexial 4/5 axes Milling, Simultaneous 5 axes Milling, Turning, Turn-Mill up to 5-axes and WireEDM. SolidCAM has the Certified Gold-product status from SolidWorks and provides seamless, single-window integration and full associativity to the SolidWorks design model including parts, assemblies and configurations. SolidCAM has today more than 12,000 seats installed. The company has been on a very rapid growth path since it implemented the SolidWorks integration strategy with annual growth rates over 30%. SolidCAM is sold by a worldwide reseller network in 46 countries.

www.solidcam.com

SolidCAM UKSolidCAM UK was formed in January 2002 by the current directors to sell and support SolidCAM in the United Kingdom and Ireland. Since then, SolidCAM has been on a rapid growth path with annual growth rates more than 30%. SolidCAM UK is based in Barnsley, South Yorkshire, where a fully equipped training facility can be found for training and support purposes. All the people at SolidCAM UK are from engineering backgrounds, essen-tial for the smooth operation, knowledge of the customer’s requirements and levels of support.

SolidCAM UK Ltd.Unit 25 BBIC Innovation Way, Wilthorpe S75 1JL Barnsley South, Yorkshire United KingdomPhone: 44-1226-241744 Fax: 44-870-1126338E-Mail: [email protected]

Finished panel after trimming has been performed

BS Plastic A/S, Denmark 07/07

ProductiveBS Plastic A/S is one of the pioneers in plastic manufacturing in Denmark. In 1958 Steen Simonsons’ father started the com-pany in Risskov near Aarhus and the com-pany was 100% craftsman oriented until the 1990`s. BS Plastic supplies plastic parts in series from 5 to 500 to a variety of premium manufacturing companies ranging from film machinery producers to windmill factories.

It was almost a revolution when in 2004 BS Plastic bought their first CNC controlled ver-tical milling center to enhance its production capabilities.

»It was a giant step for us and so many things have happened since then« explains managing director Steen Simonsen, who since has increased the number of machines eightfold, a very essential development for the company.

»Flexibility is the keyword in our organisa-tion. We have to be very fast in changing from one job to the next, because our sur-vival is depending on the small series of parts« Steen Simonsen continues. Therefore the flexibility was an important factor when he invested in a top modern production line.

Together with the CNC controlled vertical milling machines, BS Plastic A/S also invested in the SolidCAM software. The results of this investment has had a direct positive effect on the company’s profitability. Programming time has in some cases been reduced to a tenth, and where a complicated part in the past could have taken more than a week to produce, it can now be done in less than one day.

High software requirements

»SolidCAM is easy and fast to use, and has minimized the time it takes from receiving a 3D model file from a customer till we start producing the part« Steen Simonsen states. On top of this it is very easy and cheap to change the setup if needed.

»Technically we have to be in the front, but at the same time we require our software to be easy to comprehend and fast to use

and work with« Steen Simonsen says, after having experienced his employees being able to use the software after only 3 days of training from the reseller.

Despite the current trend that many com-panies are moving their production to coun-tries where the costs are lower, he prefers to continue the production in Risskov.

» We must be at the front end «

SolidCAM, fully integrated in SolidWorks quickly generates from the SolidWorks model a ready-to-go CNC program, which the machines use for milling the mold for the plastic part.

SolidWorks is used to design customer products for many different industries.

Managing director and owner of BS Plastic, Steen Simonsen is very satisfied with the much more flexible production which the com-pany has gained after moving to SolidCAM.

»Our know-how is so large that we can com-plete the products in house and with our software the machines are doing most of the work« the director says, fully convinced that outsourcing is not an idea for BS Plastic A/S.

The fact that SolidCAM is meeting the demand of simplicity can be vouched for by CNC programmer Kim Herstal. He has 27 years of experience with CNC-program-ming and every day he sees the difference between SolidCAM and the previously used programming methods.

Easy and more effective

»It is a giant relief that SolidCAM is fully inte-grated in SolidWorks. We are now able to machine a 3D model and have it working the first time. We see the part and the machining simulation on the computer screen and can rely on it working on the CNC machine the

first time we run it.« Kim Herstal continues that SolidCAM is easier and more effective than its competitors. The simulation tools in SolidCAM are extremely powerful and there-fore there is no doubt that the part will be milled exactly as shown on the screen.

»It is impressive to see how an advanced 3D model is easily transformed into a 10.000 lines NC program which can be run directly on the machine,« the experienced programmer says. Kim Herstal is in close dialog with SolidCAM’s Danish subsidiary which supports him closely. His sugges-tions for improvement have been realised; for example BS Plastic requested special functions related to thread milling that have now been implemented in SolidCAM. This co-operation is an ongoing process and SolidCAM manager Bo Pedersen is fre-quently visiting the plastics part manufac-turer to provide ongoing support and tech-nical assistance.

BS Plastic A/S, Denmark 07/07

© 2007 SolidCAM GmbH. All rights reserved.All brand and trade names are property of their respective owners.

SolidCAMFounded in 1984 by its Managing director Dr. Emil Somekh, SolidCAM provides manufactur-ing customers with a full suite of CAM software modules for 2.5D and 3D Milling, High-Speed Machining, Multi-sided Indexial 4/5 axes Milling, Simultaneous 5 axes Milling, Turning, Turn-Mill up to 5-axes and WireEDM. SolidCAM has the Certified Gold-product status from SolidWorks and provides seamless, single-window integration and full associativity to the SolidWorks design model including parts, assemblies and configurations. SolidCAM has today more than 12,000 seats installed. SolidCAM is sold by a worldwide reseller network in 46 countries. SolidCAM has been on a very rapid growth path since it implemented the SolidWorks integration strategy. In the CIMdata NC Software Market Assessment Report, CIMdata named SolidCAM as the worldwide fastest grow-ing CAM vendor in 2003, 2004 and 2005 with revenue growth rates of +39.4 percent, +51.1 percent and +40%.

www.solidcam.com

BS Plastic A/SBS Plastic A/S supplies plastic parts in volumes from 5 to 500 to premium manufacturing compa-nies ranging from film machinery makers to wind-mill facturies. The efficient manufacturing of parts is done in a modern shop floor that includes four vertical milling centres, two turning machines and two sheet metal milling machines. The machines are working 24 hours a day, and are producing 70 to 80 percent of the company’s output. For the programming of the CNC machining centers BS Plastic successfully utilizes the integrated manu-facuring solution “SolidWorks+SolidCAM”.

www.bs-plastic.dk

SolidCAM drives BS Plastic’s four vertical milling centres, two lathes and two sheet metal milling machines. These CNC controlled machines manufacture 70-80 percent of BS Plastic’s production.

Production manager and CNC programmer Kim Herstal is in close cooperation with SolidCAM’s Danish subsidiary for the benefit of both partners.

Application Report Essai Corporation, USA 03/07

Productive

Essai drives high-volume production of test boards with SolidCAM integrated CAD/CAM

Chosen as one of the fastest growing private companies in California’s Silicon Valley by the San Jose Business Journal, Essai Corporation has become one of the leading providers of products for testing the reliability of IC (integrated circuit) chips in just three years. One of the primary reasons the company has grown so quickly and succeeded in a highly com-petitive market is its integrated approach to manufacturing, according to Nasser Barabi, founder and owner.

“Before beginning operations, we conducted an extensive qualification program to iden-tify the best combination of design, simu-lation, and manufacturing technologies to support our business,” Barabi recalls. “Our objective was to implement a system that provides seamless integration between all necessary applications, including design (CAD), analysis (CAE), manufacturing (CAM), and enterprise resource planning (ERP). Our main requirement was that all systems had to be fully integrated with the SolidWorks® 3D CAD program and operate on SolidWorks solid modeling data. We needed to manage high-volume production efficiently and effec-tively to succeed and wanted to avoid having to work with different applications and sets of data.

“By implementing an integrated CAD/CAM system from the very beginning, we believed we could build efficiencies into our pro-cesses and avoid the growing pains we were likely to face later on if we had utilized the traditional approach to CAD/CAM,” Barabi adds.

After evaluating a variety of SolidWorks-compatible CAM programs, Essai selected SolidCAM® software, a fully integrated machining application that uses the embedded SolidWorks CAD system as its modeling engine, to support its NC program-ming and manufacturing needs. The com-pany chose SolidCAM as its CAM solution because it is fully integrated with SolidWorks and provides manufacturing programmers

with greater control over how the software creates manufacturing paths for simulta-neous 5-axis machining. “At Essai, we are manufacturing sophisticated, custom parts, and SolidCAM provides the robust capa-bilities our manufacturing personnel need to produce accurate, quality parts consis-tently,” Barabi says.

Maintaining design intelligence

Because SolidCAM uses SolidWorks CAD software as its geometry engine, there is no disconnect between design models and machined models, maintaining the design intelligence of the model throughout the pro-cess. Non-integrated CAM systems that uti-lize import/export schemes to bring design geometry into the machining applica-tion strip away valuable relationships and design intelligence. With the integrated SolidCAM/SolidWorks approach to CAM, Essai main-tains the inherent intelligence of its designs.

“When we develop a design in SolidWorks, we are doing more than creating a model for a single manufacturing run,” Barabi explains. “We are often building upon or modifying a previous design and bring all the intelligence of the parent design through on subsequent designs. If changes are made on the man-ufacturing side, we capture them on both the design side and the manufacturing side

Automating IC test system manufacturing

Using the SolidCAM integrated CAD/CAM sys-tem, Essai has achieved greater manufactur-ing consistency and more predictable manu-facturing outcomes.

With the SolidCAM system, Essai realizes improved accuracy, such as on the manufac-ture of this Active Cooling System, which is used to manage the temperature of semiconductor devices during high-volume automated testing.

because SolidWorks and SolidCAM are fully associative. The integrated approach has a lot of advantages, including saving time, accessing a single geometry file, and using the intelligence of our design data in a more efficient, systematic way.

Consistent manufacturing processes

Using the SolidCAM integrated CAD/CAM system helps Essai achieve greater consis-tency and more predictable manufacturing outcomes, whether it’s performing simul-taneous or positional milling, wire-EDM, or high-speed machining. In addition to saving time, maintaining a single set of product and manufacturing geometry data provides a common platform that serves as an effec-tive control mechanism from process to process.

“Consistency of process is very important to our success,” Barabi stresses. “When we create a manufacturing process today, every process that follows should utilize and build upon it. Six months from now, we will leverage what we do today because every-thing we do becomes a template for future work. We need to deliver consistency, and the integrated SolidCAM solution gives us the control we need to pick up and utilize the value accrued in past work.” According to Deniz Valle, Essai operations manager, having a common conversational language for manipulating geometry between design and manufacturing not only furthers consistency but also builds valuable input from all personnel into the machining tem-plate. “Because SolidCAM is completely integrated with SolidWorks CAD software, we are actually building our CAM program-ming within SolidWorks. This approach shortens the learning curve for program-mers, offers greater geometry editing and manipulation power to manufacturing, and provides a common tool for supporting inter-action between designers and machinists. The integrated approach facilitates discus-sion and resolution of manufacturing issues because everyone is working with the same model and the same modeler. We communi-cate issues and features a lot better working with an integrated system.”

Greater accuracy, higher volume, less rework

By implementing the SolidCAM integrated CAD/CAM system, Essai has improved its first product run success rate dramatically. Increased accuracy results in less amounts of costly rework and enables the company to run higher volumes of different parts in sequence. Barabi says the company’s suc-cess rate on first product runs has risen from about 10 percent to 90 percent, in large part because of the accuracy and con-sistency provided by an integrated system.

“We have experienced drastic improvements in our first-run success, which is significant because it allows us to queue everything up back to back and process high volumes effi-ciently,” Barabi explains. “The biggest cost in manufacturing is not related to scrap materials or machine time but to produc-tion stoppages. Whenever production stops, you lose money. Whenever production pro-ceeds unimpeded in an automated fashion, you save money. The greatest benefit of an integrated system is that it enables you to minimize the number of mishaps and shut-downs and keep production moving.”

Metrics

Improved first-run success rate from 10 percent to 90 percentIncreased high-volume throughputMaintained design intelligence of partsAttained accuracy and consistency of manufacturing processes

Application Report Essai Corporation, USA 03/07


SolidCAMSolidCAM is a powerful CAM software solution that uses the embedded SolidWorks CAD system as its modeling engine. Gold-certified by SolidWorks in 2003, SolidCAM was specially developed for workshop-oriented NC programming. As a single application, SolidCAM support the mechanical machining processes of 2.5D milling, 3D mill-ing, high-speed machining (HSM), indexial 4/5 multi-sided machining, 5-axis simultaneous mill-ing, turning, turn-mill and wire-EDM. SolidCAM postprocessors can be customized for individual requirements and specific controls so that users can generate efficient NC programs for all CNC machines. More than 24 years of continuous development has gone into the current version of SolidCAM2007 R11. Today, SolidCAM is used profitably on more than 12,000 industrial and educational workstations.

www.solidcam.com

Essai is a leading manufacturer of semiconductor test and validation interconnects and assemblies. Essai’s products are used globally by semicon-ductor manufacturers to test the functionality and reliability of leading edge semiconductors rang-ing from microprocessors to high speed switches. Essai leads the industry with offering innovative engineered solutions that enhance customer sys-tem throughput and yields.

Essai Corporation48580 Kato RoadFremont, CA 94538Phone: (510) 580-1700Email: [email protected]: www.essai.com

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Application report Frencken Brno s.r.o. 02/06

ProductiveCzech high-tech shop uses SolidCAM, the Gold-certified integrated CAM-Engine for SolidWorks, to solve the bottleneck in NC pro-gramming of modern 5-axis CNC machines

The times have passed in which the main business for contract manufacturers in Eastern Europe was the production of simple commodity parts. Frencken Brno s.r.o., headquartered in Brno in Czech Republic, today produces the most complex parts of the highest quality for demanding customers from the aeronautics and aerospace industry, for instrument and measuring instrument makers, manufacturers of medical devices and even producers of laser and radar equipment. And the progress can no longer be attributed only to advantages of location, such as lower staff costs, less labour regulations and better tax benefits. Companies such as Frencken are now playing in the big league of manufac-turing, primarily due to their well-trained and motivated staff and to bold investments made in machines and software. And the Czechs are stepping on the gas. So Frencken is not just focussing on modern vertical and horizontal milling centres and milling/turning centres with up to 5 simultaneously driven axes, but through investments in SolidCAM and perfectly customized post-processors can do NC programming very efficiently and thus use their advanced CNC machines to their full economic capacity.

Global data networking, highly efficient logistic structures and the worldwide availability of modern manufacturing technology are the fuel for the development of completely new, cross-border supplier structures. Contract manufacturers can no longer hide behind national borders and the market rules are in effect eve-rywhere. It is imperative not to loose time. Entrepreneurs, in the best meaning of the word, are now in demand, because competi-tion for the most attractive orders will continue to become more international – and even harder. What to do about this? There is no quick and simple answer. However it seems certain that con-tract manufacturers who move their process chains to a consis-tently high level with respect to quality, on-time delivery, costs and flexibility will gain market share. In the process of achieving these goals, the use of efficient CAD/CAM systems plays a key strategic role.

It also looks this way to the founder and Managing Director of contract manufacturer Frencken s.r.o. in Brno, Pavel Sobotka: “Our customers demand the highest precision and machining quality and a high degree of flexibility as well. We are meeting the steadily rising demands through well-qualified and highly moti-

Aluminium and titanium are the preferred materials for machining. The numerous customers include demanding global enterprises such as Airbus. About 700 different parts are now being manufactured for the aircraft maker and over 200 of these are being used in the new wide-bodied A 380 airliner. (All photos: Frencken, Brno, CZ)

In the fast Lane

vated staff and, of course, through contin-uous investments in modern CNC machines and equipment as well as powerful and easy-to-use software.”

And the previous investment strategy is bearing fruit. Frencken has thus grown beyond South Moravian borders to become a synonym for the highest level of precision and productivity. The company’s manufacturing services ranges from general large-volume production parts up to very demanding workpieces such as those required, for example, by the aeronautics and aerospace industry, instrument and measuring instru-ment makers, manufacturers of medical devices, producers of laser and radar appli-cations and even special machine makers. Aluminium and titanium are the preferred materials for machining. The numerous customers include demanding global enter-prises such as Airbus Industries. About 700 different parts are now being manufactured for the aircraft maker and over 200 of these are being used in the new wide-bodied A380 airliner.

A sure thing: under stringent criteria, Frencken is a certified supplier of high-pre-cision mechanical components and assem-blies. In order to maintain this attained level, the Czechs are always open to adopt brand new technologies. Thus, Frencken was the first company in Europe to intro-duce a system for the cybernetic control of production processes (CPC). New insights and developments in the field of mechanical design and communications technology are also quickly put into practice.

A basic pillar for the high level of quality is the use of CNC production machines, which at Frencken comes almost exclusively from Mazak, the Japanese machine tools manu-facturer. The Mazak CPC (Cyber Production Center) manages the optimization of pro-

duction workflow. Apart from materials, tools and CNC programs, the system also manages the efficient interplay of all other parameters for the trouble-free manufac-turing of each individual workpiece.

Even though every machine operator can pro-gram directly on the control unit, external NC programming is particularly advantageous for complex machining tasks. This applies especially to the existing vertical and hori-zontal milling centres and the milling/turning centres with up to 5 simultaneously driven axes. The originally installed, PC-supported Camware 2D software from Yamazaki Mazak offers good performance only for the NC pro-gramming of simple geometries. A real bot-tleneck! With the success and growth of the business, the workpieces to be manufac-tured were becoming more and more com-plex. Some of these workpieces were impos-sible to machine with existing resources, or could only be programmed very ineffi-ciently and inflexibly. For a certain period of time this competence gap was filled by cooperating with specialized, external CAD/CAM service providers But this kind of out-sourcing not only needs additional time and

money, but is also quite problematic for con-fidential parts in particular. And last, but not least, a lack of know-how creates dependen-cies that hardly any contract manufacturer can afford today.

Pavel Sobotka: “We couldn’t exploit and continue to develop the full potential of our high-tech equipment and our existing know-how. Today you have to consistently use 5-axis machines to profitably manufac-ture demanding parts. The possibilities of indexed and simultaneous 5-axis machining gives us major competitive advantages.” And so the leap to a CAM system supporting 5 axes was only a question of time. During the evaluation of a suitable solution, Frencken

“Pacesetter”A basic pillar for the high level of quality is the use of CNC production machines, which at Frencken come almost exclusively from Mazak, the Japanese machine tools manufacturer. The Mazak CPC (Cyber Production Center) manages the optimiza-tion of production workflow. Apart from materials, tools and CNC programs, the system also manages all other parameters for the trouble-free manufacturing of each individual workpiece.

Founder and Managing Director of Frencken Brno s.r.o, Pavel Sobotka: “High-quali-fied staff and continu-ous investments.”

Josef Pavliš, Technical Manager of Frencken Brno s.r.o.: “Indexed and simultaneous 5-axis machining gives us major competitive advantages.”

casually acquired a quite reliable impression of the capabilities of different CAM systems, through cooperation with different service providers. These were then tested and eval-uated with regard to the requirements speci-fied by Frencken.

In this process, SolidVision s.r.o., the Czech distributor of SolidCAM, was particularly per-suasive. Cooperation proceeded in several phases. SolidVision first set out to learn as much as possible about the machines and CNC controls being used. The CNC post-processors were optimized step by step during this time. In the next step Frencken and SolidVision specified and introduced the standards for data transfer. The back-ground behind this was a general problem – that the customer uses a variety of file for-mats for data transfer. But easily digestible 3D geometries are the basis for fast further processing and the error-free creation of NC programs in particular. Because most part suppliers are limited in the file formats they can work out with the customer – the cus-tomer is king, after all – the favoured file formats at Frencken were defined as DWG, IGES and STEP.

Pavel Sobotka: “During the test phase for data import and the customization of the post-processors, cooperation between the specialists of both companies was of fun-damental importance. Since then trust and mutual respect has been carried over to all levels of cooperation.” And Josef Pavliš, Technical Manager at Frencken, adds: “The excellent cooperation between our program-mers and the specialists from SolidVision was an important reason for the imple-mentation of SolidCAM in our production line. Without the professional approach and the active support of SolidVision the roll-out would certainly have not gone so smoothly.”

But this wasn’t and isn’t the only reason for the investment in SolidCAM. Pavliš: “The fea-tures of SolidCAM for milling with 5 axes are very practical and, above all, easily learned. How easy the software is to use was proven by the speed with which our programmers were able to implement 5-axis milling in prac-tice. With SolidCAM we decided on a com-plete solution without any compromises.” The absolutely most important part of the installation, the fully functional 5-axis post-processor for the Mazak Variaxis machine, is now running perfectly. And the post-pro-cessors for the other machines, such as the Mazak Integrex milling/turning centres, are now in the fine tuning stage.

The cybernetic CPC system plays a promi-nent role in Frencken’s manufacturing philos-ophy. Therefore the output of the SolidCAM NC post-processors was also customized so that all information needed about machining and tools flow directly into the CPC.

With the new possibilities opened up by the CAD/CAM system, the programming of very complex parts could be significantly accelerated. Over time SolidCAM‘s 2D and 3D machining strategies were also fully employed in complex machining tasks. The handling of some materials, titanium for instance, requires a specific approach. Here the features for high-speed milling, plunge-roughing strategies and special tool cata-logues with pre-set cutting speeds and feeds perform valuable services. A big advantage as well for Frencken is the functionality for indexed milling with 5 axes.

SolidCAMSolidCAM is a powerful CAM solution, gold cer-tified by SolidWorks in 2003, that was specially developed for workshop-oriented NC program-ming. SolidCAM, in a single application, supports the mechanical machining processes of 2.5D milling, 3D milling, high-speed machining (HSM), indexial 4/5 multi-sided machining, 5-axis simul-taneous milling, turning, turn-mill and wire-edm. SolidCAM post-processors can be customized for individual requirements and specific controls so that users can generate efficient NC programs for all CNC machines.

The experience of 23 years of continuous devel-opment work has gone into the current version of SolidCAM2006 R10. SolidCAM is now being profitably used at more than 10,000 workstations in industry and education.

www.solidcam.com

“Advantage post-processor”The 5-axis post-processor for the Mazak Variaxis machine is now running perfectly. And the post-processors for the other machines, such as the Mazak Integrex milling/turning centres, are now in the fine tuning stage.

“Trust is good – Control is better”For Frencken, measurement at a µ level of precision and tracking of parts on their own coordinate measurement machine is a must for many orders. At this point it should be evi-dent if the process chain from CAD to CAM to chip removal is running perfectly.

“No experiments”To increase the safety of 5-axis tool paths NC programmers first simulate machining completely on the computer with the virtual Mazak Variaxis machine.

Pavliš: “Because complex machining tasks on 5-axis milling centres can be easily defined in SolidCAM, acceptance on the part of the programmers was very high from the beginning. We can now manufacture very complex workpieces that would hardly be economical to manufacture without the most modern features for 5-axis simulta-neous milling.” The productivity advantage alone is not the only justification for the use of 5-axis simultaneous machining. With the use of 5 axis, high slanted side-walls of a workpiece can be machined with the circum-ference of a tilted milling tool. In addition, surface quality is significantly improved by the use of the new technology.

Still, even the best 5-axis CNC program has to be verified as realistically as possible before actual milling. “The virtual simulation of tool movements with the entire machine tool in SolidCAM is an optimal solution,” praises Josef Pavliš and adds: “We check

all machining tasks before we manufacture them on the machine. This is how we can avoid downtimes and even more importantly, avoid unnecessary collisions. Our program-mers have very quickly become acquainted with the system and are now enjoying the benefits of SolidCAM.” A minimum amount of training is of course needed to make CAD/CAM a pleasure. Because normal daily work at Frencken leaves hardly any freedom for proper qualification on the system, a binding training schedule was created for the pro-grammers. At the same time, close commu-nication with SolidVision’s technical support was set up using internet-based tools.

Pavel Sobotka: “Machines and software are always only as good as the people working with them. Qualifications initially take time and money. But these investments pay off very quickly. Through the efficient use of SolidCAM we can exploit the true potential of our machines.”

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© 2006 SolidCAM GmbH. All rights reserved.All brand and trade names are property of their respec-tive owners.

SolidCAM Ltd. E-Mail: [email protected] Internet: www . solidcam.com

Application report Frencken Brno s.r.o. 02/06

“Qualitative diversity”The company’s manufacturing services range from general large-volume production parts up to very demanding workpieces such as those required, for example, by the aeronautics and aerospace industry, instrument and measuring instrument makers, manufacturers of medical devices, producers of laser and radar applica-tions and even special machine makers.

Frencken Brno s.r.o.Jarní 48614 00 BrnoCzech Republic

www.frencken.cz

Text+Images: Dipl.-Ing. Klaus Dieter Hennecke,

Olpe, [email protected]

A breakthrough agreement of over 1000 licenses of SolidWorks and SolidCAM guarantees 3D CAD/CAM training on the highest level for 3200 students in 30 technical schools.

The twenty-first century is the century of a rapidly expanding high-tech industry while many other vocations are rapidly becoming redundant. Most young adults will not find work without further vocational training in high-tech related fields. The district authority of Freiburg and software compa-nies, SolidWorks and SolidCAM, have reached an agreement which enables the tradition-rich Feintechnikschule in VS-Schwenningen, as well as a total of 29 other vocational schools in the administrative district of Freiburg, to offer all their students 3D CAD/CAM training at the highest level.

In a highly competitive international market, Germany will only be able to keep its posi-tion in manufacturing by concentrating on advanced high-tech products. Competitors in developing countries are advancing extremely fast. The consequences are being felt and are clearly visible internationally. All established industrial countries are facing dwindling numbers of workplaces for simple manual labour. Some branches of industry have almost closed down completely. Even though Germany is the world’s largest exporter, a minimum of value creation in manufacturing is needed to earn the foreign currency needed to pay for the vital import of commodities and energy. Therefore a tal-ented and well-trained staff is needed to turn

“Theory meets practical experience” The college for precision technology in VS-Schwenningen, using the integrated SolidWorks and SolidCAM solution with modern CNC machine tools, teaches how a complete process chain can be efficiently utilised to convert one’s ideas into real products. (All images: SolidCAM/Hennecke)

ProductiveFTS college for precision technology 01/06

Groundbreaking CAD/CAM training to ensure the new generation a successful future!

innovative ideas into high quality products that are competitive in today’s world mar-kets. Such specialized personnel will only be available in sufficient numbers if the con-tents and the standards of vocational training are up to world class levels. To achieve this, Germany needs not only demand- oriented technical colleges and curriculum but also an infrastructure that is up-to-date with the latest industry technology. Here the issue of CAD/CAM, as a linchpin for modern value-creation processes, assumes a stra-tegic key role.

Let’s have a look at the combined state college for precision technology and tech-nical academic high school (FTS) in VS-Schwennigen. The tradition-rich FTS does not only combine 5 types of schools with a total of 600 students and about 60 teachers under one roof, but also serves as a model for a total of 30 vocational training centres in the district of Freiburg. Despite its tight budget, FTS decided to aim at set-ting up advanced 3D CAD/CAM training for its students.

Elmar Moeschle, head of manufacturing technology at the State Seminar for didac-tics and teacher training in Freiburg: “For a practice-oriented CAD/CAM training it doesn’t make much sense that each single technical college develops and implements its own strategy. A minimum amount of standardisation is necessary to ensure effi-cient operation of the schools. This natu-rally starts with the selection of a suitable CAD/CAM system and the qualification of the teachers. Also the maintenance, i.e. the

consistent updating of the software, is an important factor in the future organisational and financial requirements. The support pro-vided by the software reseller has a major influence on how efficient the system can be utilised for training.” Juergen Kubas, a technical teacher at the FTS, agrees with this and adds: “The more schools and col-leges that can agree on the introduction of a common CAD/CAM system, the higher the interest of an eligible and qualified vendor to support our goals in vocational

training. After all, each student will transfer the knowledge he or she has acquired into the industry. Our graduates are highly quali-fied and will find employment, with almost no exception. Therefore technical colleges and vocational training centres are impor-tant multipliers of know-how.”

With the above plan and awarded with a mandate from the other technical colleges in the district of Freiburg, the quest started in 2004 for a powerful, easy-to-use, shop-

“Investing for the future”In the end any school can qualify its students only just as good as its software tools and equipment allows. Fortunately many schools and vocational training cen-tres profit from the energetic and monetary support of the business community and active fund raising.

FTS Villingen-Schwenningen

The combined state college for precision technology and technical academic high school (FTS) is a vocational full-time college with five different types of schools: a tri-annual technical academic high school, a techni-cal college, a year long master college, a tri-annual vocational training centre where precision mechanics, watchmakers and system electronics technicians receive qualified vocational training and a technical college for IT and communications technology. With the higher education entrance qualification and an advanced technical college certificate, the FTS offers two diplomas within the general education system. All other qualifications which can be obtained are equal to the general high school diploma.

Juergen Kubas, state qualified techni-cian for mechanical engineering and technical head teacher at the FTS of VS-Schwenningen: “Integrated SolidWorks and SolidCAM provide us with all the tech-nological features we need for advanced, practice-oriented and cutting-edge CAD/CAM training.”

Elmar Moeschle, head of the manufacturing technology depart-ment at the State Seminar for didactics and teacher training, Freiburg: “A minimum amount of standardisa-tion is necessary to ensure efficient opera-tion of the schools. This is especially true for the qualification of the teachers involved in the program.”

floor-oriented and cutting-edge 3D CAD/CAM solution. Juergen Kubas, when com-paring possible alternatives, focused his attention on integrated CAM functionality: “3D design is not an end in itself. Here at FTS we operate modern CNC-controlled machining centres, Wire-EDM machines and a 3D-Plotter for rapid prototyping. In order to convey to our students the knowledge of the complete process chain, from the idea up to the finished manufactured product, an integrated 3D CAD/CAM system is needed; the system should not only support the manufacturing technologies and their cor-responding CNC machine controllers, but should also utilise and maintain a single and consistent 3D data model throughout the complete process.”

After extensive tests of various CAD/CAM systems, a clear decision was taken for the integrated SolidWorks and SolidCAM solu-tion. SolidWorks is the world’s most suc-cessful 3D CAD solution in the mainstream market and the de-facto industry standard.SolidCAM was Gold-certified by SolidWorks

in 2003, which means that SolidCAM offers seamless single-window CAM integration in SolidWorks and provides full associativity between the CAD and CAM data. SolidCAM is a powerful, easy-to-use CAM software solution for NC-programming for the man-ufacturing technologies of 2.5D milling, 3D milling, 3+2 multi-sided machining, 5 axis simultaneous machining, turning, turn-mill and WireEdm. Kubas: “Integrated SolidWorks and SolidCAM provide us with all the technological features we need for prac-tical and cutting-edge CAD/CAM training.” Next was the question of how to finance the project and how the teachers would be trained.

At the SolidWorks reseller SolidPro GmbH, Vöhringen-Wittershausen and at SolidCAM GmbH of Schramberg, Mr. Moeschle and Mr. Kubas were able to find two counter-parts who were in principle willing to greatly reduce the license fees and to support the introduction of the systems with training courses for the teachers. Thomas Ettwein, assistant headmaster at FTS: “The terms for educational use of SolidWorks and SolidCAM enable us, and the other tech-nical colleges involved, to provide a quality of technical training at the highest level pos-sible, despite our limited funds.”

Although the parties concerned would like to keep the agreed terms strictly confiden-tial, it is apparent that they are very attrac-tive. For the 30 technical colleges, a general agreement has been signed which includes 1000 licenses of SolidWorks and the nec-essary SolidCAM licenses with the corre-

sponding G-code post-processors needed for the CNC machine controllers. Vocational training centres, which have already been working with SolidWorks, will join the new licensing model. In addition, the new

Thomas Ettwein, graduate engineer, director of studies and assistant prin-cipal at the FTS, VS-Schwenningen: “The terms for educational use of SolidWorks and SolidCAM enable us to provide a quality of technical training at the highest level pos-sible, even with our limited funds.”

SolidWorksSolidWorks Corporation, a Dassault Systèmes S.A. (Nasdaq: DASTY, Euronext Paris: #13065, DSY.PA) company, develops and markets software for mechanical design, analysis, and product data management. It is the no.1 supplier of 3D mechan-ical design software for the mainstream market. SolidWorks leads the market in number of users in production, customer satisfaction, and revenue. www.solidworks.com

SolidCAM

SolidCAM is a powerful CAM solution for NC-pro-gramming which has been especially designed for use in machine workshop environments. In 2003 SolidCAM received the Gold-Product certi-fication from SolidWorks. In one single integrated application, the SolidWorks and SolidCAM solu-tion supports the manufacturing technologies of 2.5D milling, 3D Milling, 3+2 multi-sided machining, 5 axis simultaneous machining, turn-ing, turn-mill and WireEdm. SolidCAM G-code post-processors can be customised easily to meet the requirements of individual applications and machine controllers, so that users can gener-ate CNC-programs for all machine tool controllers. www.solidcam.de

licensing framework regulates the follow-up costs as it includes free-of-charge software maintenance and free updates for the first five years. As an additional bonus, SolidPro GmbH, the regional reseller of SolidWorks and SolidCAM, offers a free in-depth training

course for the teachers responsible for CAD at each school. On request, the technical col-leges can order the CAD add-on for piping. Last but not least, students will receive a SolidWorks license valid for a period of 15 months for home use, free of charge,

after their successful training. Where appli-cable, the educational license can even be prolonged.

Already about 3200 students, at the tech-nical colleges taking part in the program, are using SolidWorks and SolidCAM to get their qualification for the practical use of advanced 3D CAD/CAM software. In the light of this success, Mr. Frank Schlupp, office manager at Solidpro, wishes that, “Germany, as a manufacturing location, would see a nationwide cooperation between educa-tional institutions and industry.” As Gerhard Laegeler, the SolidCAM sales manager points out, “such arrangements as they have been agreed on in this case, could easily be transferred to other school districts.”

“Real life industrial conditions”Real life industrial conditions: At the college for precision technology of VS-Schwenningen more than 250 PCs are linked up. Utilising advanced machine tools and a 3D plot-ter, students of the integrated technical academic high school as well as prospective precision mechanics, watch-makers, system electronics technicians, masters and state qualified technicians can check their theoretical knowledge and put it into practice.

SolidPro GmbHThe SolidPro system house sees itself as a CAD integrator and a one-stop shop for complete pro-fessional solutions. Extensive CAD experience and top-notch technologies from market leading companies help its clients gain a competitive edge. According to their individual requirements, small to medium enterprises, large corporations or educa-tional institutions alike will receive specially tailored complete solutions. SolidPro is particularly com-mitted to schools, colleges and vocational training centres because only by promoting students and junior staff, the country will be able to maintain its competitiveness in the future. These princi-ples have enabled SolidPro Informationssysteme GmbH to become one of the largest resellers of the leading 3D CAD software, SolidWorks. www.solidpro.de

Gerhard Laegeler, SolidCAM sales manag-er, Schramberg: “…the agreement could easily be transferred to other school districts.”

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Frank Schlupp, office manager at Solidpro GmbH of Vöhringen-Wittershausen: “…cooperation between educational institutions and businesses could serve as a nationwide goal.”

SolidCAM GmbH Gewerbepark H.A.U 8 D-78713 Schramberg

Telefon: +49 (0) 7422 / 24 94 - 0 Telefax: +49 (0) 7422 / 24 94 - 30

E-Mail: [email protected] Internet: www . solidcam.de

text and images Dipl.-Ing. Klaus Dieter Hennecke,

www.retema.de

FTS college for precision technology 01/06

Application report Joszko Modele, Poland 02/07

Productive

How a Polish patternmaker prepares for the future

Today, computer aided design and simulation plays an increa-singly important role for designing better products. However, in order to really test the final design, engineers need to produce con-cept models and functional test parts quickly and inexpensively. In the last years, new Rapid Prototyping technologies like 3D printers helped to speed up this process. 3D Printers create physical models directly from 3D files utilizing High performance composites or elas-tomeric material.

One disadvantage of the Rapid Prototyping technologies is, that the dimensions of the produced concept models are limited. What to do in a situation, where a model of a vehicle, e.g. a car body, or a compli-cated underwater casing of a ship drive has to be manufactured?

One option is, to scale the model down to a 1:3 scale, so that the dimensions then may fit into a 3D printer. Another option is to shape a complete car body in the original size by utilizing a special plastic material called “clay”. Here, the complete digital model of the car body can be milled in clay material using a standard CNC milling machine. The resulting model can be used for design studies or wind tunnel investigations.

However, these approaches are not suitable when conceptional models require: - to have original size and- to be resistant for mechanical failures and- to perform functional tests In this case, the ultimate solution may be to manufacture the models out of the traditional material – out of wood. This is a spe-cialty of “Joszko Modele”, a leading patternmaker located in Ozimek, Poland.

High Tech from Poland

Most of the large manufacturing companies in Europe cooperate with subcontractors, which are specialized in making prototypes and patterns for newly developed products. One of them is “Joszko Modele”. Founded in 1963 in Poland, the company has had only lim-ited activities in the first years due to the political and ecomomical restrictions. There was not such a big demand from the large indus-trial customers, which generally where government owned and often had not to face competition. Therefore, the pressure of innovation in these companies was not too high, and thus the demand for pro-totypes and conceptional models was limited.

From Idea to Product

Underwater cas-ing of a ship drive designed in SolidWorks.

Wooden model of one half of the ship drive – produced by Joszko Modele

Simulation of the CNC Machining with SolidCAM

Paweł Nienartowicz, CNC Programmer, Joszko Modele

The liberalization starting in the 1980´s changed this picture dramaticly. Although Joszko Modele´s traditional customers, the Polish heavy industry, adopted the changes relatively slowly, Joszko Modele increased its business rapidly by exploiting new busi-ness opportunities in the Western European countries. The entrance of Poland into the European Community gave them a tremen-dous kick, as that Joszko Modele decided to open a subsidiary in Duisburg, Germany in order to serve its customers in Western Europe.

Pawel Nienartowicz , resonsible for the CNC Programming in Joszko Modele, states: “Now we have large opportunities across the whole continent. The large European market has many niches, which permit to choose the most suitable segment for us. On the other hand, we face more competi-tion from companies, which have a higher technological level than Joszko Modele had. So we have been forced to implement the newest manufacturing technologies in our company.”

He continues: “The challenge for us was not only to automate our manufacturing processes by utilizing the best machine and software technology, but we had also to improve our internal quality procedures and to train our 25 people to use the new tech-nology. One of our advantages is the access to young and motivated employees, which work for reasonable labour costs and are flexible to fulfill the time-critical demands of our customers.”

Changes, changes, changes …

The company introduced the new manufac-turing technology in the year 2005. Joszko Modele purchased a 5-axis CNC milling machine from the Czech manufacturer SAHOS, with dimensions of the working table of 3800 x 2200 mm. In addition, a first seat of SolidWorks+SolidCAM was purchased for computer aided design and manufacturing. The investment was partly financed by the EC Fund for Regional Development.Pawel Nienartowicz: “We decided for SolidWorks+SolidCAM because our machine tool partner SAHOS is already using this

combined solution very suc-cessfully. With SolidWorks, we have a mainstream CAD platform, which enables us to import all geometrical data from our customers and also to do design modifications if necessary. SolidCAM is seam-lessly integrated in SolidWorks, so that our programmers can operate in the same window. In case we have to modify the design, we can update our CNC programs automatically.”

An important factor for Joszko Modele is the partnership between SAHOS and SolidCAM. This guarantees, that the post processors are already vali-dated and that the data of the SAHOS machine are ready for machine sim-ulation. Especially for 5 axis simultaneous machining, the simulation and verification of the toolpaths including the machine environ-ment is essential to avoid collisions.

Pawel Nienartowicz summarizes: “With our new 5 axis machine technology and SolidWorks+SolidCAM we are now interna-tionally competitive in the wood and plastics manufacturing market.”

Application report Joszko Modele, Poland 02/07


SolidCAM Ltd. E-Mail: [email protected] Internet: www . solidcam.com

Assembly of the physical model after finish work.

Casing of the reducer, before and after the finish.

Simulation of CNC Machining and cutting on a 5-axis mill-ing machine.

Steps of the production process

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