2019cnc4-5

CNC WEST April/May 2019 www.CNC-West.com 49 and program solids in the same user-friendly interface and access Mastercam’s programming tools. When the prototyp- ing shop receives models from designers, it is not always ef- ficient to go back into the full native 3D model, modify the design in CAD, and then download it into Mastercam. The software allows programmers to mix and match wireframe, solid, and surface modeling techniques. For example, surface or wireframe elements can be added to a solid while solid components may be added to a complex surface model. “We can bring a design into Mastercam and utilize the CAD package to adjust the wireframe, change geometry, or use Solids to create new fixtures,” said Lister. “We’re saving a lot of time in our ability to tweak models and geometry on the fly in a prototyping environment.” Lister relies on the program’s flexibility to help boost de- sign efficiency. Solids features include powerful, streamlined solid modeling; user-friendly revolve, sweep, extrude, and loft commands; and maximum design potential through the use of sheet solids. He adds that, when building a prototype, the creative freedom Mastercam Solids provides is a major benefit. “The speed at which I can adjust or modify a part for manufacture, or design a fixture, really makes it powerful software for us in a prototyping environment. When collabo- rating with designers, we utilize full simulation to see de- viations from models. We use just about every aspect of the program to help us out.” One of the most challenging parts that the prototyping team produced was a thin-walled bicycle shell component that required 3- and 4-axis operations. The walls were less than 1 millimeter in thickness. Using Solids, Lister created a series of fixtures in which the first stage of the part was machined. Next, the part was sunk down into a mating fix- ture and backfilled with wax. This allowed Lister to perform second and third machining operations while the part was suspended in wax; the only fixturing at this point was the wax fixture. Lister created 3- and 4- axis toolpaths to perform complex internal surfacing and to build fixturing. The final piece had a wall thickness of .040 inches and the bounding box size was 3.5 cubic inches. “I was able to build the wax fixturing and fully assemble it, see what was going to happen by using Verify, and have it come together seamlessly to get the finalized parts,” he said. “We could see the part floating in the wax. I melted off the wax, scooped it up, and we had beautiful thin-walled parts High-speed Dynamic toolpaths were programmed into Mastercam 2019 Lathe to machine a collet. Dynamic OptiRough toolpaths provide high-speed roughing on the shock link for the Demo 8 bike. Mastercam 2019 Mill was used to program high-speed Dynamic toolpaths for the Stumpjumper link. Stumpjumper rear suspension link in various stages of production. Stumpjumper rear suspension link in various stages of production High-speed Dynamic tool- paths were programmed into Mastercam 2019 Lathe to machine a collet. Dy ic OptiRough tool- paths provid high-speed roughi g on th shoc link for the Demo 8 bike. Mastercam 2019 Mill was used t program high-speed Dynamic toolpaths for the Stumpjumper link.