Jointmedica Ltd., based in Worcestershire, UK, produces Class 3 implants in the orthopedic sector, and has, in its product portfolio, an innovative mobile-bearing Knee Replacement, as well as development activities relating to Hip Resurfacing and the manufacture of custom-made devices for specific patients created directly from CT scans.

Development is done in-house!
The high-level development activities can now be undertaken in-house at Jointmedica’s facility in Hallow, utilising ALPHACAM’s computer-aided machining software. As well as allowing them to take advantage of the brain trust and Intellectual Property available via the company’s founder, Prof Derek McMinn, ALPHACAM assists the design team to further explore these innovative new designs and incorporate new materials driving the advancement of Orthopaedic Hip and Knee Replacement surgery, therefore exacting controls, and the highest quality, is paramount.

Technical Director, Roger Ashton, says: “If we consider the Hip Resurfacing market in isolation, several years after the procedure began, a small number of patients suffered physiological problems due to hypersensitivity to various metals. The end result was that a small percentage had bearing related failures. This led to a sharp decline in the use of metal-on-metal articulations in the Resurfacing context. It is Jointmedica’s purpose to work with alternative bearing materials such as ultra-high molecular weight polyethylene, using the successful Resurfacing methodology to generate a product that will re-establish the Hip Resurfacing market. In terms of our surgeon team, we are privileged in being associated with the most experienced Hip Resurfacing designers and surgical innovators in the world.”

When the company brought their manufacturing research and development in-house, the need for investing in a suitable machine and CAD/CAM software became apparent. Roger says: “It was clear we were going to have an interesting combination of 2D turned profiles and surface machining with milling, drilling, and slotting, and we were conscious that we had a lot of complex geometries to deal with. So, we needed a CNC machine tool and software that could manage all of our milling and turning requirements, including sometimes more than 3-axis.” And, he says, their Brother Speedio M140x2 full 5-axis CNC machining centre fit the bill perfectly. “Many products require a combination of 3-axis and 4-axis machining, plus turning operations. So ALPHACAM will always be an integral part of our manufacturing process now.”

Customizing implants
Generating custom implants at Jointmedica begins the moment they receive the patient’s CT scan, which allows them to start modelling the bespoke product. They use two CAD systems to design the solid models – mainly Creo, and occasionally SolidWorks. The files are usually sent as an XT file, STEP file, or as a DXF file for the turning cycle in the lathe software.

The company uses ALPHACAM Ultimate Mill and Standard Lathe to machine the finished product with the Brother capable of both turning and milling. Oliver Clayton, Manufacturing Engineer at Jointmedica, explains: “I take ALPHACAM’s 3+2 system and incorporate it into some of the bespoke custom devices, and then, an easier 3-axis and turning program definition on the cutting paths for a simpler, axisymmetric product. In the turning program, I mainly use the CAD side in drawing the geometry and applying the toolpath. That’s extremely useful because I can incorporate not only the model but draw my own toolpaths in there with the geometry.”
As an example, the materials for a ball and socket type of bearing, which work well when implanted in the body as a Hip Replacement, can include ultra-high molecular weight polyethylene of differing formulas, and a counterface of cobalt chrome, ceramic, or other material.

“Through accurate machining driven by ALPHACAM, material wastage is kept to a minimum, and we can also ensure the final, bespoke product is suitable for the patient,” Oliver says it’s of the utmost importance that the implants are of the highest precision. “When we come to CMM measurements they must be dimensionally correct, and ALPHACAM ensures we get the right results every time. When considering our prototyping expectations, we are comfortably achieving the industry expected tolerances and a bearing surface finish of 0.8 Roughness Average for one-offs. We know that future production capability will significantly exceed these figures, and we are confident in the solution afforded by the Brother CNC driven by ALPHACAM.”
“Due to ALPHACAM’s accuracy, I can be totally confident that ALPHACAM guarantees the product will be right first time, every time.”

ALPHACAM’s accuracy
For Jointmedica, a particular challenge facing the manufacturing process was manipulating the toolpath to get the quickest machining time for a particular part. ALPHACAM’s ability to define the best cutting tools and toolpaths allow these to be manipulated to set the quickest timescale with the best path for the device to be manufactured accurately. Oliver concludes: “When I refer to accuracy, I don’t just mean the speed and accuracy of a geometric toolpath I put over a CAD model that’s come into ALPHACAM; I mean combining a number of different types of operations – the accuracy and ease of ALPHACAM coming in and picking up at a point that I’ve designated on the software, at a later stage on the product with an alternative type of machining method. It picks up accurately, as verified with our CMM equipment, and it is always within the specified critical dimensions. This is a huge benefit.”

The latest edition of Alphacam, from Vero Software – the world’s number one CAM developer – is rich with new features ranging across the modules, making it easier to use and improve productivity.

Amongst the new and enhanced functionality:

• User interface improvements
• New 3D Machining command
• Updates to Machining cycles
• Sawing enhancements
• Simulation updates
• Automation Manager improvements
• New CAD files and versions

The overall user experience has been augmented in a number of ways, including restyled dialogs to provide a more intuitive layout, with images and tooltips included to help the user.  An example is the new 3D Machining dialog which provides the interface to multiple machining strategies in a consistent manner. Strategies available in the 3D Machining command are: Along Intersection; Constant Cusp; Cylindrical Parallel; Cylindrical Profiling; Drive Curves; and Z Contour Roughing.

The Work Plane Properties option in the Project Manager displays a window with a grid containing details of the work planes in the active drawing, such as the name and offset number, which can also be edited in the grid. Additionally, it is now possible to rename the move clamp/fixture operation in the Quick Edit window.

A new option in Drawing Notes means the Add-ins dialog will only be displayed if the opened drawing file already contains notes.

In Machining, the Cylindrical Parallel strategy now gives the option of setting the width of cut as a distance, and when editing settings, the Drawing Area will update with a preview of the tool and holder, if applicable. The machining area is indicated by a transparent shaded region around the part that is automatically updated when settings are changed in the dialog, allowing the user to visualise the effect that a change has on the operation.

Alphacam Router now includes improved foul avoidance for sawing. Previously when using a saw to cut parts, the risk of fouling other parts was increased due to the size of the blade. Alphacam 2017 R1 sawing operations now checks for fouling against all geometries selected for the same operation, resulting in toolpaths being trimmed, if necessary. This means that parts can be laid out on a sheet and all sawn as the same operation, using the automatic fouling check. The operator can use the new path extensions tool with options for extending saw paths by either, Distance, to Boundary or Pick Point, with reversing options.

For Simulator, the new release sees XY configurations supported on both the head and table.

The transfer of 5-axis toolpaths between Alphacam and the simulator has been optimised, meaning that complex operations containing toolpaths comprising thousands of individual elements are much faster. Furthermore, if program stops are included in the operation, they will now be recognised. All these improvements make the user experience more realistic and speed up the simulation process.

Automation Manager sees several new options that provide flexibility and performance improvements, these include:

• Feature Extraction – From Faces: An option that enables the user to extract the solid body outline of the part.
• For non-nested job files the ‘From Job’ option is now available in the Machining Order drop-down menu in the Processing Tab. This is now set as the default selection for non-nested job files.
• Alphacam 2017 R1 gives the ability to copy and paste styles in the layer mapping setup tree by right-clicking and selecting Copy or Paste on the menu. Settings are retained when copying, which enhances efficiency by removing the need to re-apply settings each time a style is applied to a layer. It is also possible to copy and paste a complete setup, if required.

General Enhancements
Work Volume support has been added for the Parametric Sketcher – useful with many post processors that require the work volume dimensions for the NC controller.
User configurable Default Layer Setting – useful when creating designs with set layer configurations.

Improved Solid Model Assembly Splitting Support for SolidWorks and Solid Edge assemblies.

The Area Estimate routine has been improved to take account of drilled holes.

Alphacam’s Network License Profiles allow users to save their own selection of system and module licenses as a single profile, making it quick and easy to select pre-defined license options. For example, all network licensing users can create their own set of License Profiles and copy them to a shared folder on a nominated network PC, ensuring that all users can access the same ones. A particular profile can be specified when Profiles are being configured, or an option can be checked to select one from the list displayed when the licensed application is run.

Vero Software recently hosted successful Alphacam and Cabinet Vision User Group Meet-ings at the North American divisional headquarters of parent company Hexagon Manufac-turing Intelligence, in North Kingston, R.I.

The meetings, which took place Oct. 17 and 18, delivered in-depth overviews of new prod-uct features and enhancements, as well as a preview of upcomingdevelopments.

Participants learned how to optimize the Alphacam user interface for an up to 30 percent reduction in programming time, and were given a real-time demonstration of how parts reverse engineered with Hexagon technology can be easily programmed using Vero Software.

“We scanned a part with a Hexagon portable ROMER scanning arm, generated a file popu-lated with the associated geometry, and then imported the file into Alphacam,” said Perry Boyett, Alphacam sales and services director. “From there, we were able to program the part to demonstrate how Hexagon metrology equipment and Vero solutions quickly add up to greater efficiency on the shop floor.”

In addition to being educational forums, user-group meetings are an opportunity for cus-tomers to posepractical questions to Vero staff, as well as to interact with peers.

“These meetings are designed to directly benefit our customers by offering training at no charge on certain aspects of the software,” said Paul Corey, sales engineer for Vero Soft-ware. “At events like these, our users are given the opportunity to ask questions and receive answers that will immediately help them to be more productive.”

A leading manufacturer of point of sale and display equipment is looking to expand its range of CNC machining capabilities, and says Alphacam Advanced Router, from Vero Software, is integral to its plans.

Alphacam-Programming-ASH-PlasticsA.S.H. Plastics already uses Alphacam for high quality, accurate machining of its range of sheet material, and working on complex parts that it would not be able to undertake without it.

Joint Managing Director David Archer says it is especially valuable for prototyping, as they can generally get a prototype on the machine ready for cutting, within 20 minutes. “When we were programming manually it could take up to an hour, so there’s considerable time saving.”

They invested in Alphacam when they installed a second Rye CNC router. The software now drives their 8 x 4 three-head MG 240, and a two-tabled machine which has four heads and four tool changers. “Both machines are three-axis – which is why we wanted Alphacam, so we could machine 3D parts.”

He says accuracy is of paramount importance to them, especially where they are bonding and gluing parts together, and Alphacam enables them to machine to high tolerances. “If we were to be out by just half a millimetre it would mean the unit wouldn’t fit together, but Alphacam achieves those hyper-critical tolerances for us.”

As well as providing their 3D capability and accuracy, Alphacam readily overcame a particular major challenge facing the upfront CAD part of the operation. “We use Alphacam’s Automation Manager to import several SolidWorks files into the system at once, automatically set up the machining for different materials and thicknesses, as well as nesting. This saves several hours of programming time a week, compared to when we had to open each part file individually, save as a dxf, import it, and then nest it separately.

“It means that once the customer has approved the part design, we can integrate all the SolidWorks part files into Alphacam, the CNC operator then programs those files for each different substrate, they’re sent to the machine, checked and verified, and then go into production.” He says Alphacam’s Advanced Router module ensures a seamless transition from CAD to CAM. “Setting up the geometries and toolpaths is incredibly easy, compared to how it used to be when we had to plot it all out manually and write line after line of G-code. Now, it picks up the required material and thicknesses, and generates everything for us, creating the NC code within minutes – again, saving considerable time.”

Along with the point of sale material for end-users such as Claire’s Accessories and Tesco, A.S.H. Plastics also manufactures a range of products for the engineering sector, including stillages for car dashboards during transit on transporters.

While some of the products only require lasering on their two laser machines, a growing number need to be finished on the CNC routers. “In particular this is when we need to do rebated slots. ItPart-Machining means we profile on the lasers, then use Alphacam to create a jig which we’d fix into place on the router, and Alphacam programs the CNC to carry out the routing operations and machine the slots as required.

“For example, we needed to create a locking door which we designed in 3D CAD. We had to laser the profile, then used Alphacam to create the NC code for a rebated two-part slot.”

The company, which employs around 35 staff at its 32,000 square foot premises in Wolverhampton, has two front-end operatives working with Alphacam – one of whom also runs the CNC machine, using all aspects of the software – and a further shop floor worker who specialises in running the CNC machines using the programs which have been produced for him.

A member of the Alphacam technical support team helped to set up the software initially, creating their first programs. “We were taking on a new contract which required a certain level of 3D machining, and we didn’t have the capability to carry it out at that time. An Alphacam engineer worked closely with our part files, demonstrating how to program those particular components.”

The latest release of the game-changing Alphacam CAD/CAM software ensures that users can exploit the full power of their PC.

Alphacam 2015 R2 is 64-bit compatible, meaning its programs can utilize all  available memory. “With 32-bit computers only able to work with 2GB, irrespective of how much memory is onboard, some large files are extremely difficult to work with,” says Alphacam Technical Manager Paul Green. “We gave a high priority to this development, as it means end users can now process large files without any issues arising.”

Amongst the full array of new and enhanced functionality in Alphacam 2015 R2:

The GUI includes a new fully customisable radial menu. “It means users can set up as few or as many commands as they need.”

For Advanced 5-Axis Machining, while the previous release of Alphacam introduced surface machining, considerable enhancements in 2015 R2 give many more advanced options, including wire frame machining for effective trimming, and multi-axis roughing which allows roughing to the actual contour, removing any unnecessary fresh-air machining. Side Wall Axial Relief Feed (SWARF) machining reduces 5-axis cycle times and gives a better surface finish through effective side-of-tool machining. The strategy is to finish the part in one cut, through constant cutting conditions giving increased material removal and a constant low cutting force, along with simultaneous 5-axis vector orientation providing full access to machining areas.Enhanced Feature Extraction makes it easier to find features on orthogonal panel faces. “There is now the option of finding holes and contours on any panel face at the same time, speeding up panel processing.”

Another major aspect of new functionality has been added to Part Management, with full associativity between a part and its copy. Whenever an original part is amended on Alphacam 2015 R2, there is the option to automatically update the copy.

Improved on-screen realism is achieved through Rendered Z-Level Geometries and Material Textures.  “By rendering Z-level parts we’re making them visually clearer to the user,” says Paul Green. “And users can now apply any texture, whether it be metal, wood, granite, plastic or composite, so that it looks on-screen how it will look on the machine. Rendered clamps and fixtures can also be shown on a full machine configuration.” A command in the Rough Finish cycle – Previous Tool Profile – automatically uses the profile of the previous tool to generate the new tool path to machine corners where form and shaped tools have left material there. A new function in Nesting now identifies parts by name, rather than number as in previous releases. “As well as the part names showing in the nest on-screen, they also appear in reports. It helps to make in formation more relevant – users can see at a glance which part is on a nested sheet.” Solidworks Assembly Support considerably speeds up processing. While Alphacam has been able to import Solidworks files of individual parts for many years, one click now brings in a full assembly file containing all the parts. Subtle changes to Part Modeler give higher quality image previews, along with commands for part manipulation including rotation around a specific point or axes, and zoom to a cursor.