Autodesk is ushering in its new 2017 Computer Aided Manufacturing (CAM) products for a multitude of advanced manufacturing applications ranging from CNC mill- and lathe-programming to complex mold and die manufacturing. These new products combine the heritage of industry leadership in CAM software from Delcam with Autodesk’s 3D design and manufacturing prowess, presenting Autodesk CAM customers with a powerful and unique user experience.

Autodesk’s 2017 CAM solutions include enhanced versions of FeatureCAM for automating CNC programming; PartMaker for precision part manufacturing with Swiss-type lathes; PowerMill for designing the most complex molds, dies and other components; PowerShape for the design of 3D complex parts; and PowerInspect hardware-independent inspection software. New capabilities for each of the 2017 CAM products are detailed below.

“Manufacturers need to iterate and innovate faster than ever before to stay competitive as the marketplace is redefined by a new future of making things,” said Mark Forth, manager of manufacturing industry strategy at Autodesk. “Autodesk’s new 2017 CAM products are designed to help our customers learn, improve and master advanced manufacturing techniques that ultimately lead to better designed and functional products being brought to market more quickly and efficiently.”

Next month during the IMTS 2016 conference in Chicago, IL, Autodesk will outline its broader vision and software portfolio to support manufacturers in this new competitive environment. In addition to the technologies unveiled today, the company will also spotlight solutions for additive manufacturing, CAM, composites and more.
FeatureCAM 2017 and PartMaker 2017

Autodesk FeatureCAM is an easy-to-use solution for milling machines, turning and turn/mill centers, and wire electrical discharge machines (EDMs). The automation tools within FeatureCAM help manufacturers reduce programming time, allowing parts to be made faster. They also increase programming consistency for maintaining part quality. The 2017 version of the product includes the following improvements:

New programming capabilities for dual-path Swiss-type lathes, further improving its range of CNC machine support
Ability to import and view product and manufacturing information directly from a model in order to help visualize design specifications
Access to functionality that allows pre-drilling when using Vortex toolpaths, ruling out the need for helical ramp moves
FeatureCAM
In addition to the features above, PartMaker 2017, which enables complex, high-precision part manufacturing with Swiss-type lathes, is now available within the FeatureCAM 2017 Ultimate product tier. The two products in combination form a complementary bundle that effectively addresses the programming requirements of today’s manufacturing shops.

“We have a great history working with FeatureCAM, and when we were asked to evaluate the new Swiss lathe functionality, it was a no-brainer for us,” said Bill Karas of Karas Kustoms. “In the past, I had been programming the Swiss machine by hand. Using FeatureCAM for the Swiss machines saves our company a ton of time with excellent results.”
PowerMill 2017

Autodesk PowerMill 2017 takes the ability to easily and effectively manufacture the most complex molds, dies and other components to new heights. This latest version includes the following new features:

More efficient 3D offset finishing toolpaths, greater simulation controls and constraint-based logic to optimize non-cutting link moves for safer, more efficient machining
For the first time, PowerMill also provides strategies to create turning routines for use on 5-axis mill-turn machines
These improvements continue to make PowerMill the ideal choice for manufacturers looking to solve the most demanding of 3-axis, high-speed and complex multi-axis applications.

PowerMill-Turning-Large-1920×1080
“PowerMill helps us to maintain a high level of consistency in our programming, which directly and positively affects time in process and customer satisfaction,” said Randy Lee Meissner, CNC Department Supervisor at Dynamic Tool and Design. “We develop processes where each engineer is using the same techniques and the same tools, so there is no variation among the work everyone is doing. In the old days, there may have been some hand-fitting, but today we can count on uniformity in the molds we create from order to order.”
PowerShape 2017

The design of 3D complex parts just became more effective with the following improvements to PowerShape 2017:

Accessibility shading to identify areas of a part that cannot be machined with 3-axis machining alone
A new rib capping tool allows users of EDM technology to automatically create surfaces in order to stop cutting tools from machining slots that will be produced by EDM. Hundreds of surfaces are created in a single command, saving hours of manual modeling.
The PowerShape electrode wizard offers improved EDM hardware integration for shop-floor burning
Finally, regular users of reverse engineering tools can benefit from improved fitting of surfaces to imported triangle meshes
PowerInspect 2017

Autodesk PowerInspect simplifies the inspection of complex shapes by providing a single solution for a wide range of measuring equipment. PowerInspect 2017 includes the following new features:

Support for portable measuring equipment, coordinate measuring machines (CMMs) and On Machine Verification (OMV) are offered in a single package for PowerInspect Ultimate users. This improves productivity and flexibility by making it easier for operators to select the most appropriate measuring equipment for each job.
The ViewCube feature offers specific benefits for visualizing inspection results and creating inspection reports
A single click mechanism to recall the principal CAD viewpoints, making the creation of consistent inspection report images faster and easier than ever before
Improvements to point-cloud performance now allows users to take advantage of the improved capabilities in the latest scanning equipment
A dedicated point-cloud single point item provides an easy way to evaluate target points from laser scan data

What are the products and technologies that Delcam will showcase at DMI 2016 in Bengaluru?
We will be showcasing some of our most sought after products and solutions during DMI 2016. Some of them are:-

PowerSHAPE: The 2016 release of PowerSHAPE Pro software will help users to complete complex tooling designs faster and more easily. A combination of new, more efficient, code and the extension of multi-threaded calculations to many commonly-used tasks will make the software significantly faster than any previous version. One key enhancement allows groups of features to be copied between two solids in a single operation.  While the features do not need to be of the same type, the most common application is expected to be in copying patterns of holes from one solid to another, for example, from one mould plate to any other plate in the mould stack.

PowerMILL: The main enhancement in PowerMILL 2016 is the ability to mirror complete machining projects in one operation and to maintain the machining characteristics automatically, for example to specify automatically whether climb or conventional milling should be used in each section of the toolpath.  Previously, only individual toolpaths could be mirrored. Automatic mirroring saves considerable time whenever tooling is needed to produce right- and left-hand versions of a part.  It will also be faster to program the machining of moulds for symmetrical objects, since it will be possible to program one half of the core or cavity and then mirror the toolpaths to generate the complete program. A new PowerMILL module for creating ribs in tooling makes it much easier and safer to program the machining of cavities for narrow ribs, even when the cutter’s length is much greater than its diameter.  Using the dedicated rib-machining strategy gives a better surface finish than using a standard finish-machining option and also improves efficiency by limiting the number of air moves.

PowerINSPECT: The latest release of PowerINSPECT makes it easier to complete fast and accurate inspection of complex assemblies, including mould tools.  The main improvement for users of CNC CMMs is the addition of support for MCR20 and FCR25 probe change racks.  PowerINSPECT can now incorporate probe changes into fully-automated measurement sequences.  The new version also includes automatic feature extraction for point-cloud batch inspection, easier navigation of the history tree, better control over RPS alignments and new options for collision checking.

The role TAGMA and DMI plays for the industry…
TAGMA has been an exemplary body, leading the Die-Mould Industry in the country towards better enablement and technology in the past 25 years. I believe DMI is probably one of the largest events of its kind in this part of the world. The die mould fraternity is a closely knit one and this event projects that to end customers enabling them with a macro perspective that helps build more confidence as well as note the massive innovation that players in this domain undertake.

With the Make in India campaign rolling out across the country, the business value of participation is invaluable. With a focus on manufacturing, tools, dies and moulds will be fundamental to the success of this campaign; networking with contemporaries, peers and customers at a single venue will multiply opportunities and learning’s for all.

What are the latest developments in the CADCAM industry? Please take us through the current technology trends in the industry…
The CADCAM industry is working constantly to improve the customer experience and provide them with tools that will help them be more efficient and precise. Technologies like MachineDNA that help assess various parameters & kinematics of a machine tool and provide appropriate output to the NC program in order to ensure that the cutting is optimal is something that I believe will help machinists immensely. Our parent organisation Autodesk is also leading the disruption with the Future of Making Things (FOMT) in manufacturing. Through FOMT, a better, faster decision making process, ability to work effectively with newer materials and fabrication methods (Advanced manufacturing) and enabling these technology solutions on the cloud will help transform businesses quickly, safely and efficiently, whilst delivering maximum competitive advantage to our customers.

India is home to many CAM solution providers, what would be your strategy to stay ahead in the competition?
There are indeed several CAM solution providers and it is not just true for India alone. The CAM market is fragmented and I see some consolidation in the industry now. However, the key factor in our line of business is people and support. We have been in India as a direct office for the past 16 years and arguably are the leading CAM supplier in the country. Through a dedicated and pro-active team that we have across 14 offices in the country, we are constantly in touch with our customers to understand their key requirements and pain areas. This helps us being more responsive and adaptive to their needs. We also invest heavily in R&D.

Please share with us the growth trends of die and mould industry in India – and what are the key drivers of this industry in the manufacturing sector?
The die and mould industry in India has had a steady growth largely, but has also seen its share of slowdowns as well. To a large extent the die and mould industry has based its growth on the automotive sector and therefore the result relies more importantly on automotive growth in the country (or across the globe for that matter) than anything else. However, this is soon changing with organisations investing in new technology and continuously innovating – rather than being just mould or tool suppliers. The OEs too are doing their bit by involving tool making companies in their development plans so that the entire chain becomes efficient. According to me, competence, delivery schedules and impeccable quality are the three most important drivers of this industry in the manufacturing sector.

What will be the impact of programmes like Make in India, Digital India and Smart Cities project on the die and mould industry?
Programs like Make in India, Digital India and Smart Cities are envisioned to transform the country and each of these will result in a better quality of life for citizens. Naturally, the die and mould industry will play a key role in helping these programs to be efficient through innovative product/tool designs, material selection and durability, aesthetics and functional quality of the end products – and these factors are true for all of the above programs for building a brand – India.

The above programs are also expected to bring in investments, newer technologies, budding scientists and engineers, veteran industrialists and the Government towards a common goal of building brand India. This is an opportunity that comes with a privilege and the die & mould industry can take a leadership role in transforming change from the roots.

Do you think SMEs in India are ready to adopt high end technologies like CAM?
SMEs in India have been adopting high end technologies like CAM and CNC machines for a long time now. It is now time to think beyond these and look at the ever changing consumer needs, changing materials and the methods of producing these new age materials. I feel that we have reached a stage where companies start investing not only in high end technologies, but also in employees, knowledge and analytical capital. This will help SMEs transform into larger and more responsive organisations.

Tell us about the growth of your company and your growth expectations in the next financial year…
We have been growing double digit YoY for the past 16 years now. We now supply to a diverse portfolio of customer industries as well as products. I am very positive of our continued growth in the coming FY as well.

Over the past five years, German automotive toolmaker Konrad Schäfer Modell und Formenbau has switched all its static and portable CMMs, as well as its hand scanners, to Delcam’s PowerINSPECT inspection software. The results of standardising on a single software have included lower training expenses, greater staff flexibility and perfect CAD compatibility.

The company’s roots in manufacturing models date back 110 years, originally in Muehlhausen, where Konrad Schäfer GmbH now has an additional production site. “We see ourselves as one of the leading manufacturers of design and data control models, inspection and function cubing, and control gauges for the European automotive industry,” explained Jörg Große-Beilage, head of the modelmaking department, which has been based in Osnabrueck since 1962.

Additional activities include models for vehicle interiors and prototypes for vehicle lights, as well as jigs and moulds for aerospace carbon fibre composites.

Konrad Schäfer GmbH transforms customers’ ideas into reality – five to ten years before they are ready for batch production – with the help of innovative approaches to prototyping, the newest CAD, CAM and metrology technologies, and a modern machine shop. Herr Große-Beilage also proudly pointed out that technical skill is still a crucial part of the organisation’s philosophy, something that wouldn’t be possible without motivated and well-trained staff.

At nearly every workstation, there is a CMM, either a stationary manual or CNC CMM, or a portable measuring arm. The range of measuring machines are of different ages and from Mora, Zett Mess and Stiefelmayer, while the portable arms are from FARO.

“Metrology is an important part of our core business,” says Herr Große-Beilage, one of the reasons Konrad Schäfer GmbH continually invests in this area; not only in machines but also in staff training. “Our target continues to be that both measurement engineers and model builders know how to use our metrology systems”. That was also one of the reasons why Konrad Schäfer GmbH started to convert their whole range of metrology machines to a universal software.

A wide range of solutions from different companies was reviewed as part of the selection and decision-making process, “but in the end PowerINSPECT convinced us the most.”

“The decision to purchase PowerINSPECT was absolutely spot on, even from today’s perspective,” says Herr Große-Beilage. On one hand this is because of the good CAD compatibility. Components in all CAD file formats can be inspected with PowerINSPECT, something that was particularly important for Konrad Schäfer GmbH.

In addition to the extensive feature set and the support from Delcam, the user-friendly interface was a key factor for Herr Große-Beilage and his team. The CAD File Manager in PowerINSPECT is just one example; this makes it easy to manage component groups. The decision was also easy because PowerINSPECT offered by far the best price-performance ratio.

Konrad Schäfer GmbH currently uses 16 licenses of PowerINSPECT, which have been purchased progressively. At the start, in 2009, the company purchased two licenses and contracted to buy four additional licenses in each subsequent year.

Portable coordinate metrology is becoming increasingly popular at Konrad Schäfer GmbH. Five Faro Gauge arms are already used, all supported by PowerINSPECT. “Manual measuring arms have the advantage that I can measure quicker than with a stationary measuring machine because I can just measure one zero point and then inspect everything else from top to bottom without adjusting anything,” explained Herr Große-Beilage. “But because I’m limited by the part size, the movable stand measuring machine is definitely better suited to a whole car”.

Christian Wollbrick, a metrologist who works daily with the software, confirmed that PowerINSPECT’s ease-of-use means that even untrained staff can get started immediately. “Elements can be interactively selected in the CAD view, for example,” he said. “This makes inspection programming significantly easier and quicker, something that is really useful when you just work with the system from time-to-time.”

Moreover, the ability to define a critical measurement point in advance and to be led to that point by PowerINSPECT during the measurement is very valuable. “This is particularly beneficial with hand-held devices, as it guarantees consistent and repeatable measurements.”

Work on inspection cubes depends on being able to work as flexibly as possible, yet at the same time in a reproducible way with a three-axis CMM. “Test cubes are reference models that simulate the body in white. Subsequent parts that occur in different car types can be built in or attached to them,” explained Herr Große-Beilage. “So you can test in advance, whether they truly fit or check that there are no interfering edges and also if joints and radii are correct. Every manufacturer has different reporting standards but we can implement them really quickly with PowerINSPECT.”

Delcam will demonstrate the latest releases in its range of CADCAM software for mouldmakers at the Die & Mould International exhibition to be held in Bangalore, India, from 6th to 9th April. New releases will be on show of the modelling-for-manufacture CAD system, PowerSHAPE, the PowerMILL CAM system for high-speed and five-axis machining, and the PowerINSPECT inspection software.

The 2016 release of PowerSHAPE Pro software will help users to complete complex tooling designs more quickly and more easily. In addition, a combination of new, more efficient, code and the extension of multi-threaded calculations to many commonly-used tasks will make the software significantly faster than any previous version.

One key enhancement allows groups of features to be copied between two solids in a single operation. While the features do not need to be of the same type, the most common application is expected to be in copying patterns of holes from one solid to another, for example, from one mould plate to any other plate in the mould stack.

The main enhancement in PowerMILL 2016 is the ability to mirror complete machining projects in one operation and to maintain automatically the machining characteristics, for example to specify automatically whether climb or conventional milling should be used in each section of the toolpath. Previously, only individual toolpaths could be mirrored.

Automatic mirroring saves considerable time whenever tooling is needed to produce right- and left-hand versions of a part. It will also be faster to program the machining of moulds for symmetrical objects since it will be possible to program one half of the core or cavity and then mirror the toolpaths to generate the complete program.

A new PowerMILL module for creating ribs in tooling makes it much easier and safer to program the machining of cavities for narrow ribs, even when the cutter’s length is much greater than its diameter. Using the dedicated rib-machining strategy gives a better surface finish than using a standard finish-machining option and also improves efficiency by limiting the number of air moves.

The latest release of PowerINSPECT makes it easier to complete fast and accurate inspection of complex assemblies, including mould tools. The main improvement for users of CNC CMMs is the addition of support for MCR20 and FCR25 probe change racks. PowerINSPECT can now incorporate probe changes into fully-automated measurement sequences.

The new version also includes automatic feature extraction for point-cloud batch inspection, easier navigation of the history tree, better control over RPS alignments and new options for collision checking.

Commenting on the event, Vineet Seth, Delcam’s Managing Director for South Asia & Middle East, said, “We have been participating in the TAGMA Die & Mould exhibition for over a decade now. It is interesting to note that, over the period, many of our die-mould customers have diversified their businesses into emerging markets like automotive component manufacturing, aerospace component manufacturing, composites manufacturing, automation products, healthcare components etc. This has been possible due to their wide experience in precision manufacturing as well as their willingness to invest in technology products that offer reliability, flexibility and speed. I’m really looking forward to the event in Bangalore, as this region offers a mix of all of the aforementioned emerging markets. The exhibition will allow us to share with visitors, the benefits of investing in our Advanced Manufacturing Solutions software that is renowned for being reliable, easy-to-use, robust and fast.”

Delcam has released the 2016 version of its PowerINSPECT inspection software, the world’s leading hardware-independent 3D inspection solution.  The new release includes greatly enhanced options for section measurement, more comprehensive collision avoidance, improved point cloud inspection, the ability to add notes to reports, and improved user control of CNC surface inspection routines.

Section inspection has been improved with easier creation of sections, better visualisation and enhanced reporting.  The enhanced options for section editing in PowerINSPECT 2016 include a slider that can be used to move the section through the part with real-time updating of the CAD view.  A specific value for the section intersection can still be entered if required.

New graphics options help with visualisation and reporting.  In the CAD view, the default option highlights the section cut and displays a semi-transparent representation of the material in the foreground, providing an accurate 3D visualisation of the section in place on the part.  During section creation the shading is updated dynamically as the section moves through the model. Alternatively, the near side can be hidden completely, or the complete CAD model can be shown in a solid colour as before.

Once the desired section has been chosen, the inspection path can be generated automatically.  The points generated can be edited if necessary.  The section can also be viewed and reported as a 2D true view of the section profile that is currently selected.

As with other PowerINSPECT measurements, the results of the section inspection can be viewed as spot confetti, deviation lines or vector lines.  The results can be displayed either on their own or as part of a larger inspection sequence.

Automatic collision detection was introduced in PowerINSPECT 2015, with probe paths adjusted automatically when a direct move between inspection features would result in a collision.  A new collision-free mode extends this capability by automatically creating links between inspection features as necessary.  If a potential collision is detected, the software automatically creates and calculates a new linking path that avoids the obstacle.  Collision avoidance is recalculated when the order of the inspection sequences is adjusted in the sequence tree.

Intermediate paths can still be created or updated manually.  This is required when the CAD model does not include complete information about the physical reality, for example if clamps or fixtures used to hold the part are not included in the CAD data.

PowerINSPECT 2016 has improved reporting with the ability to include additional user-defined information.  New ‘Report Note’ items allow the user to insert additional observations, including text and pictures.   As with all other items in the report, the notes can be shown, hidden and re-ordered within the report.

The formatting of labels has also been enhanced, particularly for GD&T items.  New options have been added to the dialog for session settings to enable further control of the label display.  Furthermore, the label sizes can be edited in the session settings and grid lines can be displayed for clearer reporting.

A number of enhancements have been added for inspections based on point clouds.  Firstly, point clouds can be imported from DMT and STL triangle files.  Scanning acquisition performance is improved and points can be saved from a point-cloud scan each time there is a pause during the scan.  Several point-cloud items can also now be created in a single point-cloud session without having to leave the full-screen acquisition view.

CNC surface inspection has been improved, making it easier to produce consistent results across a batch of components.  New surface inspection groups provide better user control of point naming, and the positioning, contents and formatting of report images.  It is also possible to reference CNC surface inspection groups directly in RPS alignments.

Finally, there are significant usability improvements for the CAD File Manager.  It is now possible to import one or more CAD files by dragging and dropping them into the main graphics window.  The highlighting and visualisation of individual objects in CAD models is further improved, making it easier to identify named objects and levels.

Parker Aero Tooling Solutions, a rapidly expanding aerospace toolmaker, has changed to Delcam’s PowerMILL CAM software to remove a programming bottleneck that was limiting the company’s productivity.

The company, which has been based in Accrington in the North-West of England for over forty years and is now in its second generation of family ownership, produces a wide range of tooling, including jigs and fixtures, exclusively for the aerospace industry.  It has been closely involved in designing and manufacturing tooling for many of the world’s most prestigious aircraft programmes, including all Airbus platforms, plus the Eclipse and Honda VLJ programmes.  Virtually all of the tooling is made as a ‘one-off’ so developing the most efficient machining approach for each project involves a steep learning curve.

Most of the staff are time-served toolmakers with a wealth of aerospace knowledge, and their skills and expertise are needed on almost every job.  In addition, Managing Director, Mike Parker, puts a strong emphasis on encouraging direct interaction between his staff and his customers.  “We have built up a detailed knowledge of our customers’ equipment so we can make tooling that will be easy for them to install and efficient for them to use,” he claimed.

“We have always designed our tooling with the same CADCAM system that is used by most of our customers, and have been happy with that aspect of the software,” said Mr. Parker.  “However, we have ten machines, including several five-axis machining centres, all demanding programs.  We were experiencing a serious bottleneck with our two seats of the machining software as we couldn’t supply toolpaths quickly enough.”

Mr. Parker investigated a number of alternative CAM programs before deciding on PowerMILL.  The software provided a complete machining package that covers all the bases for the range of projects at G. Parker Aero Tooling Solutions, plus the price was very competitive.  In addition, the company was already using Delcam’s PowerINSPECT inspection software and had been impressed with both the software and the support provided.

Even though the staff have only been using PowerMILL for a few months, the effects have been dramatic.  “We have effectively doubled our programming capacity with the three seats of PowerMILL because the software is so much easier to use,” reported Mr. Parker.

Craig Cooke, Production Manager, had used an alternative CAM system for all his working life but hasn’t found anything that PowerMILL can’t do.  “All four people that we have trained in PowerMILL have been very motivated.  Of course, introducing new software has seen some difficulties but nothing insurmountable,” he said.

A key benefit of PowerMILL for G. Parker Aero Tooling Solutions is that it is purely a machining package so it is much easier to introduce onto the shop floor.  “It is much simpler to exchange knowledge between the different users because it is so much easier to use,” said Mr. Cooke.

“The calculation times are around 25% faster, which, along with the ease of use, means we can generate programs more quickly,” he continued.  “Stock models are much easier to use in PowerMILL so we are able to reduce air cutting and shorten machining times with rest machining.  We had always struggled with creating undercuts but programming for disc cutters is extremely quick in PowerMILL.  The surface finish we get now is very good; it is extremely smooth with no faceting.  This has reduced polishing time by an average of 20%.”

Operator Robbie Cooke has also been impressed with the Delcam software.  “PowerMILL is very graphical with pictures to tell you what the system is going to do,” he explained.  “The measuring tools for angles and undercuts help me to choose the best strategy and cutting tools to use, while the automation in the software means that I can complete programs more quickly.  I’ve only been using the software for a few months so the simulation tools are really valuable.  They make it easy to see if you are going wrong and to put it right.  They also give me the confidence to put jobs onto the machine straight away.  I’ve already programmed all sorts of jobs – press tools, jigs, fixtures and so on.  PowerMILL handles it all.”

The productivity boost from introducing PowerMILL has come at an important time for G. Parker Aero Tooling Solutions.  “Business is pretty good,” claimed Mr. Parker.  “We already have enough projects lined up to make 2016 a better year than 2015.  We have plans to add more five-axis machines as they always seem to be fully booked and we will be recruiting two more apprentices.  Extra training, including more PowerMILL courses, is also planned for the existing staff to make them more flexible so we are able to take on more projects.”

Delcam has added more five-axis machining functionality in the 2016 R2 release of its   FeatureCAM CAM programming software. Other enhancements include improved control and simulation capabilities for multi-axis machines, plus options to reduce both programming and machining times.

FeatureCAM was the world’s first feature-based programming software when it was launched in 1995. Constant development since then has ensured that the system has retained its leadership in programming speed and ease of use, while an increased range of strategies has been added to provide more efficient toolpaths that give greater productivity on a wider range of machinery, including turn/mill machines, five-axis mills and wire EDM equipment.

FeatureCAM 2016 R2 introduces the ability to machine features aligned to the Z axis by using the C axis, rather than by moving in the X and Y axis. This option, which is commonly known as polar milling or polar indexing, can be used in situations where the machine cannot travel beyond a certain linear point. Instead, the C axis can be used to rotate the part within the machining envelope. It can be most helpful when machining parts with a circular profile, when machining times can be reduced and surface finish improved.

Another addition to FeatureCAM’s flexible machine architecture provides support for the W-axis option in machine tools such as horizontal boring machines. This addition can be used to control and simulate moveable live spindles that can extend the travel limits of the Z axis to help avoid collisions.

The new release also includes an improvement to automatic tool selection – the inclusion of a check of the diameter of the tool shank. If the shank diameter is found to be larger than the diameter of the cutting portion of the tool, FeatureCAM will choose a tool of the appropriate length to avoid collisions of the shank with the part.

FeatureCAM 2016 R2 provides settings to position and index a turret within a part-handling feature when programming turn/mill machines. These settings can now be shown within the machine simulation, making it possible to pre-empt and fix potential collisions during part-handling operations.

Two options will allow more efficient machining. Firstly, relative plunge, which now supports two-axis spiral and zig-zag toolpaths, can be set to allow the tool to rapid to the plunge clearance location, rather than feeding to it. Secondly, curve sorting has been added to give better control of the order for machining multiple curves within a single feature. This can be set automatically using options including ascending or descending in X, Y or Z, or using the shortest path to achieve the quickest cycle time.

Machine design files can now be selected on a document level, making it easier to check visually which file is loaded. The same dialog also makes it quicker to edit the set-up location of the component and to change the machine-design file for the post-processor that is currently loaded.

Finally, FeatureCAM allows a post-processor document to be generated. This document helps users to understand the capabilities of the post-processor that is loaded currently.

Delcam has added an ABB robot fitted with a Fronius CMT Advanced welding head to the range of manufacturing equipment at its Birmingham site.  The new unit will be used mainly for research into the programming of robots for the additive manufacturing of metals with Delcam’s PowerMILL Robot software.

Cold Metal Transfer welding was initially developed by Fronius to join materials with different properties, in particular for welding aluminium to steel.  The process uses very high frequency movement of the wire to give a clean, spatter-free material transfer.  It provides a stable, reproducible deposition of material that Delcam believes should have great potential in metal additive manufacturing.

The ABB robot arm offers six axes of movement, with an additional two axes, tilt and rotation, provide by the table holding the material.  This additional flexibility allows parts to be oriented into the optimum position as they are being built so enabling complex shapes to be created with less need for extra support structures.

PowerMILL Robot makes it as easy to program a robot for machining as it is to program a five-axis machine tool.  As a fully-associated application inside PowerMILL, users have access to all the multi-axis machining strategies within PowerMILL and can use all the system’s project management options to manage, store and retrieve data.

As well as making it possible to program robots for additive manufacturing, PowerMILL Robot can be used for tool-to-part applications, especially for machining large parts, such as composite panels that need to be trimmed, or for part-to-tool applications, such as grinding or polishing.

Autodesk subsidiary, Delcam, is to be an Event Partner at the DMG MORI Open House to be held at Deckel Maho in Pfronten from 26th to 30th January.  A total of 90 machines will be displayed at the event, including six world premieres.

Delcam programs to be featured at the Open House will include the latest releases of the PowerMILL CAM system for high-speed and five-axis machining, the FeatureCAMfeature-based programming system and the PowerINSPECT inspection software.

The main enhancement in PowerMILL 2016 is the ability to mirror complete machining projects in one operation and to maintain automatically the machining characteristics, for example to specify automatically whether climb or conventional milling should be used in each section of the toolpath.  Previously, only individual toolpaths could be mirrored.

Automatic mirroring saves considerable time whenever tooling is needed to produce right- and left-hand versions of a part, such as press tools for the nearside and offside of a car.  It will also be faster to program the machining of tooling for symmetrical objects since it will be possible to program one half of the core or cavity and then mirror the toolpaths to generate the complete program.

The 2016 version of FeatureCAM includes a range of enhancements to give high-quality results on all types of machine tool, including complex mill-turn equipment and five-axis machining centres, while retaining the rapid programming times for which the software is renowned.

The most significant new option is the ability to duplicate the physical constraints of the machine tool in simulations in FeatureCAM.  Machine-tool limits can be added to the models to be used in the simulation for three-, four- and five-axis milling machines, for turning equipment, and for mill-turn machines, including those with multiple turrets and/or multiple spindles.  It is then possible to check that the chosen machine tool is capable of completing the proposed program for all types of equipment, from the simplest lathe to the most complex multi-tasking machine.

The latest release of PowerINSPECT makes it easier to complete fast and accurate inspection of complex assemblies.  The new version includes automatic feature extraction for point-cloud batch inspection, easier navigation of the history tree, better control over RPS alignments and new options for collision checking.

Mints using Delcam’s ArtCAM CADCAM software to produce their designs were winners in multiple categories at the 2016 Coin Of The Year (COTY) Awards.

The Awards, which are organised by Krause Publications and sponsored by World Coin News, will be presented to the winning mints during the World Money Fair to be held in Berlin from 5^th to 7^th February. A selection of the winning coins will be displayed on the ArtCAM stand at the Fair.

The most prolific winner using ArtCAM was the Austrian Mint, which was recognised in three categories following votes from an International Panel of judges. The Mint won in the Best Bi-Metallic Coin category with a 25 euro silver and niobium coin highlighting the science of evolution, in the Best Silver Coin category with its 20 Euro coin commemorating the fall of the Iron Curtain, and in the Most Artistic Coin category with a gold 50-euro coin celebrating the Gustav Klimt painting, Judith II.

One of ArtCAM’s earliest customers, the UK Royal Mint, won the Award for Best Circulating Coin. The two pound bi-metallic coin, which marked the centenary of the First World War, depicts Lord Kitchener on the reverse.

Another longstanding ArtCAM user, the Royal Canadian Mint won in the Best Crown Coin category. Crowns are silver or copper-nickel clad coins with a diameter between 37 and 45 mm. The Canadian $20 silver coin features a view looking up at a maple-leaf tree.

A 10 zlotych silver coin won the Most Inspirational Coin category for the Polish Mint. This coin honoured the birth of Jan Karski, who smuggled evidence of the Holocaust to the Allies in a hollow key.

The final win by an ArtCAM customer came from the German Mint, with a 10-euro silver coin commemorating the 300th anniversary of Daniel Fahrenheit’s invention of the mercury thermometer. The coin won the Most Historically Significant Coin award, an award recognising coins that highlight events that occurred at least 100 years ago.

ArtCAM Product Manager Rob Newman said, “We are delighted that, once again, so many of our longstanding customers have achieved such well-deserved success with their innovative and imaginative designs. ArtCAM works very closely with most of the world’s mints and is always looking for ways to improve not only design but also security features, and manufacturing efficiencies. Many congratulations to all of the winners.”