See how Slice Mfg. Studios and ARCH Cutting Tools - Mentor in Ohio use multi-task machines and GibbsCAM software to manufacture complex parts fast.
CHALLENGE
- Produce complex parts in one machining center with one setup.
- Program multi-axis CNC machines with a CAM software solution that has a single interface, machine simulation, and good post-processor support and is trustworthy, repeatable, and commonly used by workers in the area.
SOLUTION
- GibbsCAM® CNC programming software by 3D Systems
- Willemin-Macodel 508 mill turn machines with robots
RESULTS
- Eliminated variability and multiple operations and setups.
- Reduced errors and downtime.
- Cut cycle times by up to 80%.
- Reduced lead times by up to one third.
- Improved speed to first part, part quality, and tolerances.
In 2016, Randy Theken founded Slice Mfg. Studios in Akron, Ohio, as a result of his medical implant company, NextStep Arthropedix, struggling to find contract manufacturers that were able to provide the services they needed. So, basically, they’re engineers who started a contract machine shop.
Since then, Slice has established itself as an end-to-end, one-stop shop providing services and solutions for the medical device and industrial communities—from design, development, prototyping, and mechanical testing to final production and sterile cleaning/packaging. The high-end, full-spectrum manufacturing studio is FDA-registered and ISO 13485-certified with classed clean rooms. What sets Slice apart is the number of capabilities under one roof, from front-end to back-end operations.
“In our business, what’s important is speed to first good part. It's critical that we have the machine capability coupled with the software capability to work quickly.”—Joe Lah, General Manager, Slice Mfg. Studios, Akron, Ohio, USA
“I don't know that we would even have the ability to pull off some of the parts that we're making without the multi-axis equipment.”—Joe Lah, General Manager, Slice Mfg. Studios, Akron, Ohio, USA
The Equipment: Multi-Task CNC Machines and 3D Printers
Slice specializes in combining 3D additive manufacturing and precision machining into their workflow. With their multi-task machining (MTM) equipment, they can deliver high-precision parts in one setup from bar stock or a metal 3D-printed part. In addition, as part of their additive manufacturing capability, Slice has metal 3D printers that use implant-grade titanium powder for medical implants and a ProX® DMP 300 printer by 3D Systems that they use primarily for prototyping surgical instruments and tooling.
Multi-Axis Capability
Key benefits of multi-task machines include the ability to get at many sides without re-chucking, a single machining center and setup, and a high level of precision. Because you don’t have to handle a part through multiple operations, which involves repositioning the part, you can eliminate variability. “That's important in our business,” says Lah.
In addition, by using one machining center, they’re not inducing errors or air going from step to step or machine to machine, which is important from a quality standpoint. “When you eliminate multiple setups, you know right away whether you've got a good part or not. You don't have to rely on the stack up of tolerances that may occur from chucking to chucking, setup to setup,” explains Lah.
And, when using GibbsCAM to program the MTM equipment, Slice can see the part from start to finish all in one machining setup, which reduces errors that are inherent in multi-setup processes. Because they can simulate a part and walk through all the required tools, machining passes, and finishes in one setup in GibbsCAM, they can see things that they wouldn’t be able to see or simulate with multi-stage processing. “Therefore, multitasking equipment is really the only way to go,” concludes Lah.
According to lead CNC programmer and manufacturing technician Brad Fowler, “Part quality is better. It's more accurate. It's less set up, less human error.” Lah adds, “And it shortens lead time.”
Gary Knight, lead CNC programmer and manufacturing technician at Slice, adds: “When you take out the other setups, it's a huge time savings. The multi-task machines save you hours of programming.”
The Software: GibbsCAM
Slice Mfg. Studios has been using GibbsCAM CNC programming software by 3D Systems to program their Willemin-Macodel multi-axis machines and some mills since they opened in 2016. “There weren't any other CAM software programs that could support the sophistication of the Willemin 508 machines,” recalls Theken.
Reliability and Repeatability
Because any interference could wreak havoc on the MTM equipment, Slice needed CAM software that is trustworthy and repeatable—that it can count on job after job after job.
The ability to rely on the programming software is super important when it comes to ultra-high-precision MTM equipment, which are not run-of-the-mill machining centers that can survive a machine tool crash. You have to know that you’re not going to have any collisions or unexpected machine moves and that you can load a program reliably, through the post-processor, into the equipment and move on without any concern. “GibbsCAM can seamlessly create programs that, through the post, are reliable and repeatable heading to the multi-task machines,” says Lah.
Speed to First Part
In addition to cycle time, according to Lah, the biggest selling point with GibbsCAM is that speed to first good part. In their industry, the time invested to take a part from drawing a model to first part out of the machine can be as much as the time to make the parts; therefore, getting through those steps quickly is critical. “With GibbsCAM, we have the capability to work through multiple permutations and iterations of products with speed and efficiency that we just can't find elsewhere.”
By using GibbsCAM to surface different areas of the part versus traditional swarf cutting or milling and turning, Slice can produce the required geometries and surface finishes without post-processing and minimal front-side effort to get to the first good part. Lah notes: “GibbsCAM is really important to speed product through the shop. We have the confidence that any time we program a part, simulate and verify that program in the coding room, and then bring it out to the machine, we can have a part through first article layout, sometimes first try.”
“I get a work order, see what the job is, import those files into GibbsCAM, program my job in GibbsCAM, post my job, send it to the machine—and I get a good part,” summarizes Fowler.
“What makes or breaks us is speed to that first good part. With GibbsCAM we have that.”—Joe Lah, General Manager, Slice Mfg. Studios, Akron, Ohio, USA
Single Interface
Another time-saving feature of GibbsCAM is its single interface. Fowler and Knight say that because they don’t have to switch between multiple programs and can do everything within one interface, they're saving time. In addition, Slice saves time training new employees because they don't have to train on multiple programs.
Industry Experience
According to Theken, Slice ultimately chose GibbsCAM to program their multi-task machines because of its industry experience and reputation.
Reputation
Lah notes that GibbsCAM is widely known in the community: “With these multitasking machines, it's hard to find folks that can make them sing like they need to and like they can. With GibbsCAM, we can find programmers who really know the capabilities of the machine, can match that with the software, and get us to solutions that work, quickly.”
“We're using GibbsCAM for our multi-axis machines. We have some very good programmers on staff and, when we were looking to choose a software package, resoundingly, GibbsCAM was their software of choice.”—Joe Lah, General Manager, Slice Mfg. Studios, Akron, Ohio, USA
Post-Processor Support
Post-processor support was another critical factor in choosing GibbsCAM. According to Fowler, each machine takes a different post and, if a post doesn't match the machine, they have to edit a lot of code.
Local Support
Another bonus of working with Virtual Manufacturing is that they’re local. Knight has worked with Virtual Manufacturing for posts since 2006 and says that the support's been great. “And I don't have to wait to contact California.”
The Results: Competitive Advantage
With the multi-task machining centers and GibbsCAM software, Slice Mfg. Studios has been able to provide its medical device and industrial customers with the complex, ultra-high-precision components that they require and that most other shops can’t produce. “We're able to, in one setup, make components that might take others months and countless hours of design and programming work. Where, through the GibbsCAM software and multitasking capabilities, we're able to go from program to finished part in days,” confirms Lah.
With GibbsCAM, Slice has taken pain away in a speed that allows their customers to continue business without worrying about the supply chain or whether they're going to meet project deadlines.
“Without GibbsCAM, I don't know how we would operate in this shop. It takes a powerful piece of software to be able to go from our customers' ideas and requirements into real, tangible solutions and products.” Lah concludes: “I whole-heartedly recommend GibbsCAM for anyone who’s considering buying some multitasking equipment or even changing their current software. GibbsCAM has given us the capability to be more efficient and to make components that couldn't be made any other way.”