Paul Teutul Jr., star of TLC's hit reality TV show "American Chopper", used GibbsCAM to machine bike parts in time for the Sturgis Rally.

Gibbs and Associates, developer of GibbsCAM® software for programming CNC machine tools and a Cimatron company, announced that Paul Teutul Jr., star of TLC's reality TV show "American Chopper", chose GibbsCAM in order to challenge and beat his father's shop in designing and building custom motorcycles for the fall season of the TV show.

For the last six years, American Chopper has featured Orange County Choppers, the custom motorcycle builder co-founded by Paul Teutul, Sr. and Paul Teutul, Jr., who left the shop to start his own design firm, named Paul Jr. Designs. The fall season of American Chopper, appropriately titled "Senior vs. Junior," will follow Orange County Choppers, which now belongs to Paul Sr., and Paul Jr. Designs, as the Teutuls challenge each other. Paul Jr. Designs planned to unveil two new motorcycles at the Sturgis Motorcycle Rally, so they had to meet that tight deadline as well as TLC's shooting schedule.

GibbsCAM Gives Paul Jr. the Speed to Beat His Deadlines "I don't believe we would have met the Sturgis deadline – maybe not even our shooting schedule – without GibbsCAM," said Teutul Jr. "With our committed schedule, we didn't have the time or patience to learn some cumbersome CNC programming software. We had to be very selective in finding a CAM system with optimal capabilities and the ability to program anything we threw at it for our chosen CNC. That's why we chose GibbsCAM, for its reliability and ease of use. Our machinist, Mark Harris, found GibbsCAM to be extremely flexible and easy to use, and we were really grateful for the terrific support that we received from the local Gibbs representative. We look forward to similar success using GibbCAM for other bike parts throughout the season, and for our future design projects."

Paul Jr. Designs programs its Haas CNC machine, and its supplier's CNC, with GibbsCAM.  The first parts, which were required for the Sturgis Rally unveiling, were some twisting 3D "spider webs" to be mounted on a motorcycle's wheels.  The complex parts are not a typical first project for any CAM-system user, especially in the current instant, where introduction to the system was less than a month before the Sturgis deadline.

Programmer-machinist Mark Harris had eight days to model and machine six pieces, each composed of two different (front and back wheel) spider webs, in addition to modeling and machining other webbed trim parts and tending to other responsibilities. "This was my first introduction to GibbsCAM," he said, "and it's incrediblyGibbsCAM Gives Paul Jr. the Speed to Beat His Deadlines easy to learn and much easier to use than the system I have used for years. The GibbsCAM modeler enabled us to make a machinable model with the flexibility required for easy modification, while the programming modules let us try different approaches to machining, which were required because the parts were a real challenge to machine."

The "lace" of the spider webs is 3/8 inch thick. "The fragility made machining very time-consuming," added Mark Harris. "We were fortunate to have that software for machinability.  Modifying the front-wheel web to fit the rear wheel, without destroying the integrity of the design, was easier than anticipated. Any delay or difficulty would have prevented the unveiling at Sturgis."

For more information about GibbsCAM, or to locate your local GibbsCAM reseller, call 1-800-654-9399, or email [email protected]. Information about GibbsCAM is also available at the company's website,