Saul Reyes, Algeb lead mill machinist/programmer, uses Mastercam CAD/CAM software to toolpath a microwave communications part.
Family owned and operated, Algeb CNC Machining, Inc., was founded in 2006 by Beto and Laura Samperio. Today, the Oxnard, California-based job shop offers CNC turning, milling, Swiss machining, and design and production planning services. It serves several industries while focusing on microwave communications, automation, and deep-water applications.
Algeb derived its name from the first initial of each Samperio family member’s first name: spouses Adalberto (Beto) and Laura, and their children Gustavo, Emily, and Brandon. The name is quite fitting as Algeb CNC Machining is truly a family operation.
Since the age of 16, Gustavo Samperio worked for Algeb as a machinist. At 18, he attended college and earned a degree in manufacturing engineering. After graduation, he joined Haas Automation, Inc., (Oxnard, California) as a manufacturing engineer before returning to his family’s business. One of the first purchases Samperio made as Algeb’s shop operations manager was the newest version of Mastercam® CAD/CAM software (CNC Software).
“We heard a lot about the latest Mastercam release,” he said. “We had an outdated version on an old computer that was grandfathered in, but the programming process was slow. We needed to upgrade.”
Mastercam model depicts multiple planes and offsets for multiaxis machining on a 5-axis trunnion.
At the time, the most pressing issues that Algeb faced were training its CNC team and speeding up its programming processes. Before upgrading to the new Mastercam release in 2021, Samperio and his father, Beto, handled much of the programming but became overloaded while juggling it with administrative duties. The decision to invest in the latest software release was made much easier when Samperio considered technical support.
“The support from Mastercam Reseller CAD/CAM Consulting Services Inc., (Newbury Park, California) that was part of the new software purchase was a deciding factor,” he said. “Being able to call somebody and ask for help with machining specific features, rather than us trying to figure it out ourselves, was critical.”
Aluminum microwave communications part was machined with a ball endmill. Algeb CNC Machining used Mastercam 3+2 machining to perform two operations on one machine instead of two, saving valuable set-up time.
Algeb purchased Mastercam Lathe, Mill, and Mill-Turn licenses. The CAM toolpath options have been gamechangers, according to Samperio. Algeb uses Dynamic milling, surfacing, and thread milling, all of which have been especially useful on recurring jobs that require 3+2 machining on a 5-axis trunnion. One of the parts is a microwave communications component and fits inside of a 5-inch aluminum cube. Different port features are machined onto each side of the part with tolerances ranging from 0.001 to 0.002 inch. Algeb uses Mastercam to set multiple work offsets so each side can be dialed in. For this part and others, the Verify feature permits simulation from anywhere in the program and checks for material gouging and collisions.
Before troubleshooting or recommending machining strategies, the CAD/CAM Consulting Services Inc. (CCCS) team helped Algeb understand and maximize the benefits of Mastercam tools and features. For example, they helped Samperio create stock models, which are critical for accurate representation of material removal. Also, by demonstrating how to use a variety of tools, the Reseller helped Algeb avoid broken tools and fixtures.
“They’ve been extremely helpful with training and maintenance of the software,” Samperio said of the CCCS team. “When I contact them, they open up a ticket and quickly get back to me with a phone call or screen sharing.” Samperio often works closely with Frank Gonzalez, Technical Support/Instructor, CCCS.
“When we’re working with all our customers, like Algeb CNC, we strive to provide the best support in the quickest time as possible,” said Gonzalez. “Gustavo and his crew are top notch at what they do and if they are in a bind, we’re happy to work with them to get them back to where they need to be.”
Algeb purchased Mastercam’s Maintenance program, which includes upgrades, troubleshooting, and general support. CCCS helps optimize Samperio’s computer to ensure that the software runs efficiently.
“Whenever I install a new version, our reseller team conducts an extreme sharing session and they dial in all of my settings on my computer to make sure that the software runs optimally,” Samperio said. The team also develops manufacturing solutions to boost Algeb’s production efficiencies.”
“We had a part that we machined in two operations on two different machines,” he added. “I asked Frank Gonzalez if there was a way to do everything on the machine. He found a way to make it work.”
The feature was machined with a ball endmill. Normally, a machinist placed the part on the lathe to cut the final feature. But, after receiving help from Gonzalez, the Algeb machinist was able to use the same ball endmill that was in the original milling machine. The microwave communications part was a 2-inch aluminum cube. For its neck feature, the part had to be removed from the Haas VF-4 mill and moved to the lathe. Samperio wondered if Algeb’s TRT-2 5-axis trunnion could handle both machining operations. As it turns out, it could. Gonzalez helped Samperio program the part for the mill with the 5-axis trunnion.
Over the course of one year, Mastercam and 3 + 2 machining have saved Algeb dozens of hours on additional set-ups.
The Algeb management team understands that an investment in technology—software or machinery—will continue to pay off only if employees are properly trained on that technology. They quickly embraced the curriculum and convenience of CCCS online training program, which aligned with Algeb’s needs and schedules. A three-week session was the right fit for the company’s machinists and programmers. The online training follows a hybrid model: students have direct access to instructors for Q&A, weekly check-ins, and assignments through Slack, email, or phone support.
Left – Nestor Becerra, Algeb lead lathe machinist/programmer, uses Mastercam CAD/CAM software to program a turned part for a deep-water application.
Each stainless steel or titanium part required an acme thread on the front face. Right – CAD/CAM CONSULTING assisted Algeb CNC Machining in programming live tooling on a Haas ST-30Y lathe. The stainless steel or titanium part required an acme thread on the front face. The final part will be used in a deep-water application.
“We were able to conduct CAD/CAM training here at the shop after hours, so we liked the flexibility of that. We stayed after hours or set a two-hour window for training during the workday. Some people opted to come in on weekends to complete their training,” said Samperio.
In addition to online and in-person training, the CCCS team offers customer support in the form of phone calls, screen-sharing sessions, and onsite visits. For Algeb, most support is accomplished through screen sharing.
“In general, we have not needed somebody to come out and physically look at our processes. With screensharing, I can just follow along and see what our CCCS rep is doing, and they can show me the process of programming specific features,” Samperio said.
Mastercam helped Algeb program its 5-axis machine and get it to work, so the software has been critical to the company’s success, he added. Before adopting multiaxis machining, a machinist would have to place material on the mill, machine it, take the part out, then move it to the lathe and machine the final feature. The lathe required an additional set up, which usually meant two hours of labor, machining time, and tying up a second machine.
“Now, we can do everything in one place on the 5-axis,” Samperio said. “We’re a high-mix, low-volume shop, so flexibility really counts. If that lathe is busy, it’s not going to be a problem anymore because we don’t need that machine. We can get it all done in one 5-axis machine.”
On the turning side, CCCS assisted Algeb in programming live tooling on a Haas ST-30Y lathe. “We can do milling features with it on our lathe. Mastercam has been helpful in allowing us to create mill features on turned parts,” said Samperio.
For example, one turned part for a deep-water application requires an acme thread on the front face; any sharp edges must be cleaned up with live tooling. Once the acme thread is machined, an end mill and key cutter are used to remove any burrs and sharp edges to ensure that the start and ends of the threads are clean. The stainless steel and titanium parts are less than 3 inches in diameter and 2 inches long.
Since upgrading its Mastercam CAD/CAM software, Samperio said that Algeb has gained productivity and administrative improvements.
“Because we’re more knowledgeable about the software now, we are more efficient at CNC programming and more accurate with quoting new jobs because we can get a real sense of cycle times,” he said. “There are features that we haven’t used yet. We’re still drifting into the software’s possibilities, which is exciting. We don’t feel like we’re limited.”
Photos & Article provided by Gorman Pompili Communications LLC.