Integrating CAD/CAM in your Machine Shop

Moving from manual machining to CNC machining with manual G-code entry is an intimidating undertaking. Taking that a step further to introduce Computer Aided Drafting, or CAD, to model the product is even more so. Machinists are known for their engineering minds and not their computer skills, after all. New trade programs often include these skills but how is it best to approach integrating CAD/CAM in your machine shop?

Making the Choice

We discussed the pros and cons of manual versus CNC machining but let’s review a few.  Cost and training are strong factors that could slow your adoption of automated technology in your machine shop. One large order could be enough to tip the scales in favour of migrating when that job could pay a substantial part of the cost. Repeatability and accuracy are the key advantages of CNC machining. Producing a large order in a fraction of the time will demonstrate cost savings in terms of reduced manpower, scrap loss, and delivery time. One of the many advantages of CAM software, once you begin to employ it, is the ability to store many jobs in sequence to be run on the same CNC machine. CAD systems take this one step further and store designs you can recall or save as a new file with slight modifications. This reduces labour even further with a library of choices available to you over time.

How it Works                                                                                                     

CNC machines were first developed only half a century ago after just such a large order prompted the original iteration responsible for the huge shifts in manufacturing capabilities in the second industrial revolution. Points on the machined part were translated to input codes on a card punch system. Further integration moved to more advanced computers creating a CNC system that consists of a command function, a drive/motion system, and a feedback system. The command comes typically from CAM (Computer Aided Manufacturing) software in a universal G-Code language. The CAM can receive files from a CAD (Computer Assisted Drafting) software program. The motion results in the translation of codes by the CNC interface into tool selection, movement, and speed on various planes to remove material from the raw stock to produce the final product. Feedback, of course, is provided when the program is finished or an error occurs. Additional software enhancements or stand-alone software can provide further production feedback by collecting data that can benefit all levels of sales, finance, maintenance, and machine operators to create further efficiencies.

How to Integrate

That is a lot of computers. Especially for a shop that still runs manual machining. Integration may look like taking a few smaller steps or jumping right in depending on your comfort level and your budget.

Step One – Budget

The first step needs to address your budget. Consider business grants and loans, cash on hand, and business equity to determine what your budget can safely handle. Perhaps one new machine completely integrated with CAD/CAM software will satisfy your first step. Or a CNC machine is the only upgrade you can justify using manual G-Code entry. Each situation is unique and finance must be addressed with clarity and certainty.

Step Two – Investigation

Attend trade shows, compare notes with other machine shops, and ask for demonstrations from software companies. Use all of these opportunities to understand the advantages and disadvantages of different software options. Only look at the equipment that fits your budget. Used equipment may allow you to move into a higher production capacity. Your investigation should also include a full assessment of equipment on hand and efficiencies you could improve with what you currently have. And be sure to research the markets you want to enter. Check your competition and consider what niche market you could serve. This research process could be months, or even years, of investigation before you feel educated enough to make a decision.

Step Three – Staff Training

In a smaller shop, you, the owner, might be the one training on the new equipment. Or you may choose to hire software programmers to address that part of your business. Prepare for a learning curve, with mistakes and lost profits along the way. Most reputable software suppliers will provide training and support. Mastercam, for example, provides a Signature part profile to help you understand the complete process. Updates to their software reconfigure all these Signature Parts so you are always ready to train new staff and make the training smoother. CAM software has become so intelligent it can help train new employees with programming that catches errors before you begin machining.

Step Four – That First Production Run

After all the research, budgeting, installation, and training, it’s time to run that first production run. Consider pricing the job at the same rates as your manual machining, or a blended price, to allow room for error as you move into computer-aided production. Use all the features available to simulate models and run a test or two before embarking on full production. Gradually reduce pricing as efficiencies become clear and errors are worked out. You are now capable of running large orders of flawlessly duplicated parts. Advertise. And write some new business!

Step Five – Further Expansion

Assess your increased business and profit margins to define what the next step in automation will be. An initial CNC machine purchase may now be ready for CAD/CAM software. A single machine with software linked may be ready for a partner machine to double production or offer a different machining approach for other new business. Follow a similar implementation path knowing the process will be easier with more experience and research under your belt.

Moving Forward

Further expansion may also include the incorporation of quality assurance tools, robotics, and artificial intelligence – all great additions to streamline processes and increase efficiency. Your shop could look very different a year from now to how it looks today with new business from new markets. Integrating CAD/CAM in your machine shop is the start of a future with technology and innovation that is only just beginning. Get ready for the ride with the Fourth Industrial Revolution.