Sérgio Fleury Process Development Engineer Embraer S.A.
“Embraer Botucatu appreciates the efficient work provided by ICAM Technologies to develop automatic programming of our Torres-Tool Universal Holding Fixture (UHF) fitted on our M-Torres 5-axis milling machine.
ICAM’s UHF solution, integrated with our CATIA CAD/CAM system, allowed us to efficiently program different skin panels and rapidly program the Torres-Tool system. ICAM’s post-processing and machine simulation also provided us with optimized NC code that allowed us to take full advantage of our Torres-Tool UHF system.
Non-automated programming of these complex UHF systems would take days. With ICAM’s UHF solution, UHF programming can be done in only a couple of hours. Embraer can now benefit from fast setup changes and safe programs that provide high-quality parts.”
Zhiyu Zhang PhD, Assistant Research Scientist Changchun Institute of Optics, Fine Mechanics and Physics, Chinese Academy of Science
“During my NC post-processor research and evaluation, I discovered ICAM Technologies – a famous post-processor development company with a great reputation. I immediately contacted a person from ICAM China who was enthusiastic and really helped me resolve a number of technical problems we had while linking our CAM system to our CNC machines.
It is always possible to handle these complex matrix coordinate changes by creating a C-program to initiate the functions we want to address on the machine, but we are not as proficient as ICAM when it comes to writing post-processors or post-processor generators. Using ICAM’s post-processor development software, we didn’t have to work hard to deal with the basic problems related to 5-axis post-processor creation. We just had to answer the questions from the ICAM questionnaire in accordance to our machine requirements. Using ICAM’s post-processing software is easy to use and more importantly, the generated code is very safe.
I can say that it was a wise decision to choose and purchase the ICAM software. With ICAM’s post-processor generator, we have been able to implement automatic cartesian/polar coordinate machining using our Haas machine and we have also implemented special machining strategies to use oblique machining with our DMG machine. ICAM’s software solution helped us maximize the use of our machine tools, shorten processing time and improve the accuracy and surface quality of our finished parts.
After deploying ICAM’s solution and consulting its technical support team, we are no longer afraid of any manufacturing challenges. Next month, a large 5-axis ultrasonic machine tool will be installed in our facilities and we plan to use ICAM to build the post-processor and run our programs, as this option will allow us to use the machine exactly the way we want.”
Valley Machine Shop Inc
Valley Machine Shop Inc., located in Kent, Washington, manufactures small to large aerospace details and assemblies and specializes in CNC Milling and Turning. Valley uses mainly Mastercam, employs 60 people and operates twenty 3-5 Axis Mill & Lathe CNC machines.
“Prior to using ICAM, getting a post-processor running behind Mastercam for a new machine was a very slow and frustrating process. Many times we started with a very generic post and had to resolve its issues in the production environment. On the contrary, ICAM started collecting information about our machines the first time we called them. They knew the correct questions to ask and the result was a nearly working post when the machine hit the floor.
Working out any post issues was quick since we worked directly with ICAM’s post engineers, who responded quickly with changes, or explanations. ICAM’s engineers are very knowledgeable and helpful and the sales representative that managed our account contacted us regularly to make sure we were satisfied with the post. I look forward to work with ICAM on new projects the future.”
Triumph Aerostructures – Vought Aircraft Division’s ICAM Software
ICAM software, a link between Engineering & CNC machine code.
“Triumph Aerostructures – Vought Aircraft Division, a subsidiary of Triumph Group, Inc., is a leading global manufacturer of aerostructures for commercial, military and business jet aircraft. The company has full fabrication capabilities and available products include fuselages, wings, empennages, nacelles and helicopter cabins. The company’s customer base consists of the world’s leading aerospace OEMs. Triumph Aerostructures – Vought Aircraft Division employs about 6,000 people in six U.S. locations.
One of the company sites, located in Nashville, TN, produces individual parts and sub assemblies for Airbus, Gulfstream, Cessna, and Lockheed Martin. With approximately 900 employees spread over two million square feet of work space, the Nashville site has 10 large CNC gantry mills, nine large assembly riveters, and a variety of smaller CNC equipment. In the machining area, there are more than 35 CNC spindles making chips. “The Nashville facility focuses on parts that are ‘long and large.’ Most everything we do is longer than 30feet,” said Lead CNC Programmer Bill Gwinn. Those ‘long and large’ parts start out as massive engineering models, many of which reside in legacy CATIA-V4 CAD/CAM data files.
Using ICAM’s Post-Processing software, Triumph has been able to convert CAD/CAM engineering data files into Computer Numerical Control (CNC) code, quickly and virtually error free. As of 2007, many parts are being developed, or imported through a newer CATIA-V5 system. Using a two step process, CNC programmers can extract the graphic engineering data (from either system) into APTSOURCE (APT) files, which are then fed into the ICAM Post-Processing software. ICAM converts the APT information into customizable code for each CNC machine.
Current ICAM Posts
Since 2007, three new Post-Processors have been developed for three different CNC machines. The first two are for Handtmann 5-axis mills; one with a single head configuration, and the second having a twin-head gantry setup. The most recent Post was developed for an older Cincinnati 5-axis Gantry mill that was ‘retrofit’ with a new Siemens 840D Control, the same control used on both Handtmann mills.
After processing the APT files through ICAM, the final output (CNC code) instructs the CNC machines to mill Aluminum billets into precision aircraft components. Typically, these large complex parts have machine times measured in days, rather than hours & minutes; and that’s with three shifts of machining. Parts this big require large programs; in many cases, multiple large programs. According to Gwinn, that’s where ICAM has paid for itself. The processing time for these programs takes about half the time as the old Post-Processor.
While ICAM has proved itself as a valuable tool, Gwinn says that his time training at ICAM was “invaluable.” The two training sessions spent helped us go beyond just using ICAM. Triumph also has an ICAM developer’s license, and used it to build the first two Posts. This also allows users the flexibility to modify any post as needed.
In the case of the Cincinnati post, Triumph was faced with a unique situation where time was a key factor in building the new post for this upgrade. Fortunately ICAM was able to work with Gwinn and help develop and finalize the post in just a few weeks. “Our goal was to use the existing APT files, over 70 of them, and run them through a new ICAM Post to achieve the same tool path” said Gwinn. Since the Control upgrade would use a different tool path method; Tool-Tip vs. the previous Knuckle-Driven method, all programs required reprocessing. “ICAM did an excellent job collaborating with us to develop the Post, in order to give us an error free CNC tool path; especially with little to no changes in the original APT files.”
Future plans for the Nashville site include using ICAM Post-Processors on all new work and any machine-control upgrades.”
Precise Machining & Manufacturing
“Precise Machining and Manufacturing specializes in manufacturing complex aerospace structures and assemblies. Our programming department utilizes Catia, NX, and Esprit to create complex 3-5 axis programs for a large variety of machine tools. CAM-POST software from ICAM easily enables us to generate the specific output for each machine tool we have.
ICAM’s trainer gave us a post building training session that was tailor made for our needs. There were no questions he couldn’t answer, or complex posting problems he could not easily solve. Since then the ICAM support team has given us very timely support whenever we have needed it.
We couldn’t be happier with our posting capabilities now. Thank you for everything ICAM.”
“Meyn Food Processing Technology B.V. develops, manufactures sells and supports machinery for Poultry processing and is one of the global leaders in its specific market. The company is headquartered in The Netherlands, has Sales Offices in 13 countries worldwide and manufactures its products in four locations in Europe and the USA.
Meyn manufactures most of its components in-house, for which it has an NC infrastructure in its Oostzaan location that consists of eight different multi-axis CNC machines with outsourced post-processor development.
The main 3D CAD system is CATIA V5 from Dassault Systèmes which is managed by Enovia Smarteam V5. CATIA is used for concept design, detail design and CAM programming of the newly developed machines. CATIA 3D CAD is used worldwide, while CAM programming is only done in the main location in Oostzaan, The Netherlands.
During 2010 it was decided that Meyn no longer wanted to be dependent on external post-processor developers and wanted to do these developments in-house, based on state-of the art post-processor development software. For this, CAM-POST from ICAM was selected after presentations from, discussions with and a proof of concept by two different software vendors.
The implementation of CAM-POST started mid-2010 and currently (May 2011) has resulted in the re-definition or new development of all required CATIA post-processors but one: the Zayer 5-axis machine is still under development.
We can say that we are really satisfied with both the CAM-POST’s capabilities for rapidly developing complex post-processors, as well as the level of support from ICAM. “
Peter Bergendahl Senior Board Engineer Burton Snowboards
“As far as I can remember, we have always used ICAM for our processing needs and the program has always been flawless. All I can say is that we have had perfect customer service with great communication, understanding of our needs, and incredibly fast turnaround on our latest update to our Post Processor. ICAM and its products have continually helped keep our company leading the industry.”
Raymond Mark Director of Manufacturing .decimal, Inc.
“.decimal relies heavily on technology to deliver custom, patient specific medical devices to our clients around the globe. As cancer care advances, the parts we are asked to make are becoming more complex. ”
“To accurately and quickly process these requirements, the company has added Mazak 7-Axis multitasking CNCs to the facility. In parallel, the need for the other industry segments we support such as defence and aerospace, to reduce there transitional costs and schedule compression has us exploring the limits of these machines’ capabilities.”
“We needed a post-processor that would work with our CAM system to seamlessly integrate these machines into our internet based manufacturing business model. ICAM has been able to fill that need with not only a great tool but also prompt and thorough customer service.”
Geoff Haines Managing Director Desktop Engineering
Implementing ICAM’s Adaptive Post-Processing™ Solution, AVPE and Shape Machining have increased machining efficiency, while reducing NC programming and machine cycle times! Check out our video from Desktop Engineering – ICAM’s official dealer in the UK
“While working through a course in manufacturing and CAM in NX 9.0 at the University of Illinois at Urbana-Champaign (UIUC), it became clear that in order to conclude the final portion of my course, manufacturing on a simple CNC machine, a post-processing software was required. We were tasked with the initial setup and configuration of a K2CNC machine. While doing this, the included CAM software proved to be cumbersome and it lacked what we considered to be relatively basic features for changing and customizing tool-paths. NX 9.0 CAM software was much easier to use to achieve the desired result which is where CAM-POST Foundation comes in. CAM-POST Foundation allowed us to take the output files from NX, and convert them to G-code which could easily be interpreted by the K2CNC machine since no NX compatible post-processor was available. CAM-POST Foundation made all of our more complex class projects possible and its easy to use interface allowed me to create a post-processors which worked well with our simple CNC machine and even allowed us to extend its capabilities beyond what we had previously available with the stock CAM software.”
Paul Gerardy Systems Engineer Ingersoll Cutting Tools
“Like many companies these days, we changed ownership a few years ago. As part of the transition we lost our mainframe based CAM system and about 15 in-house developed, FORTRAN based post-processors. On top of that we had to make the transition in three months! We selected ICAM based on its proven track record and flexibility to handle the post-processing work for our new Pro/NC CAM system.”
“With the tremendous customization capabilities of ICAM, along with excellent customer support, we were able to rapidly develop a number of post-processors under extreme time pressure. There were a wide variety of machine and controller combinations to support and ICAM certainly provided the flexibility that we needed for a smooth transition.”
Martyn Grist Manufacturing Process Lead, 787 Program Boeing Winnipeg
“ICAM is our selected technology partner, because of the magnitude of their experiences with advanced multi-axis post-processors, expert knowledge of CATIA V5, current relationships with 787 Program suppliers and their in-depth understanding of our unique programming objectives.”
“I found that the CAM-POST product was able to do everything I wanted to do and even more. The application staff is extremely helpful, knowledgeable, supportive and professional. In times of crisis, the sales and development team quickly responded to our needs.”
“FMI’s move to ICAM’s technology and support resources ensures our manufacturing infrastructure is operating at peak performance. This allows FMI to consistently meet the operational and competitive effectiveness that our valued Aerospace customers demand.”
Dave Ferrell Business Unit Leader Metalex Mfg. Inc.
“I wish to express my appreciation to ICAM for the custom NC post-processor developed for our DMG DMC200FD. The diligence put forth by ICAM on this project has provided us with a post-processor that allows us to produce complicated bladed hardware utilizing simultaneous 5-axis machining.”
“ICAM’s expertise with developing customized NC post-processing solutions for DMG machines has increased our productivity and saved us time and money. With the success of our first DMU 80P post-processor, ICAM has developed customized solutions for all our DMG machines including our very complex DMP 60S 6 sided bar machine. Using ICAM, we do not have to do any manual edits at all after posting.”
“Also, with the help of Virtual Machine, we are now able to detect over-travel limits and to avoid collisions. Thank you for providing the link from our CAM system to our DMG machines and controllers.”
“At Abcor Pty we fabricate parts for all types of industries including Aerospace & Defense, Electronics,Telecommunications and Automotive. We required an NC post-processing solution that could work effectively with our Neos TRICEPT 805 – 5-axis Milling machine – CAM-POST was the answer.”
Brian Brown Systems Engineer Volvo Construction Equipment
“After the ownership change at our facility, management provided a new and committed vision towards the future. When I was brought on board, I was told we want a “state of the art” manufacturing system. After three months of research within the Volvo group, I arrived at the conclusion that a corporate solution did not exist.”
“After my prior experiences with ICAM, knowing ICAM’s flexibility, ICAM’s experience level of quality, commitment and experience, we realized no other post- processor would be as flexible and agile as we require. We have three CAM packages utilized at our facility in Shippensburg. We wanted one solution for three packages. Here at Shippensburg, we currently have active licenses for Wildfire IV Pro-Manufacturing, Mastercam X3, and Siemens NX6. We know that CATIA is in our foreseeable future.”
“We selected ICAM as our partner for the future growth of our facility because of its commitment to quality, customer service (both in customer support and product development), flexibility to interface with our multiple CAM packages and ICAM’s ability to deliver customized multi-axis post-processors in a short period of time.”
“In the past year, ICAM’s commitment to customer service and quality has been exemplary – from dealing with support on our custom post- processor development to requesting a license server that could be utilized on a virtual machine. I know if I phone support my issues will be solved by the end of the day.”
“The management at ICAM should be proud of their employees for their responsiveness, courteousness and professionalism at every level of their staff.”
“It is my pleasure to recommend ICAM to other professionals and programmers whenever the possibly arises and I look forward to continuing our partnership into the future.”
Jonnie Fish, NC Programmer Gardner Group Limited ICAM Technologies customer since 2004
ICAM’s CAM-POST NC post-processing development software allowed us to move away from using only 3-axis mills and allowed us to take maximum advantage of modern 5-axis milling machines. This enabled us to minimize the need to re-position our parts, improve our productivity and ultimately lower costs. Additionally, my ICAM sales and support contacts are always there to respond to my requests for information in a timely and efficient manner.
Aaron Schwaiger NC Programmer C.E. Machine Company
C.E. Machine Company, Inc. is a one-stop source for all machining, assembly, and kitting needs. Located in the heart of the Air Capital of the World, C.E. Machine has called Wichita, Kansas home for more than 40 years and is located just east of Wichita’s Dwight D. Eisenhower National Airport. C.E. Machine has a total of 25+ CNC Machines with three palletized systems totaling 161 available pallets. AS9100 Certified. CNC Lathes, Grinders and 3, 4, 5 Axis CNC Equipment.
ICAM has provided C.E . Machine with a comprehensive solution for post-processing and verification through their CAM-POST and integrated Virtual Machine software for both MasterCam and CATIA. Before we purchased ICAM, programmers at C.E. Machine had to generate NCI through the CAM software, use a third party post-processing software to post, and then import all part, stock, and tool models into a separate verification software before programs could be sent to the shop floor. With the solution ICAM has provided, programmers now use a single software suite to do all of the above simultaneously. This saves time and removes the potential for error when moving data between the different software. The ICAM Virtual Machine verification software has also proven to be more user friendly, intuitive, and customizable than the verification software we used previously.
ICAM has become a trusted partner who has always been available with immediate support as we have developed our post processors and virtual machines to get the most out of our machine tools.
Tracey Rohde, Project Manager Kohler Global Faucets Division
“In keeping with Kohler’s long history of quality, it was critical we have posts developed to accommodate our advanced machining practices. ICAM not only met our challenge, they exceeded our expectations.”
“ICAM provided Kohler with an extremely talented Engineer, without whom, we would have continued to make edits after posting. ICAM’s CAM-POST is so flexible that together we were able to create highly adaptive posts for our CNC machines. Today we post and forget about it.”
“Special care and planning goes into manufacturing prototypes. We require a wide variety of machines to make these vehicles go from the drawing board to the assembly plant and CAM-POST has the capability and flexibility to suit our manufacturing needs.”
“We had been searching for an NC Post-Processing solution for our 5-axis machines with Siemens Polynomial NURBS controllers for quite some time. The only solution was CAM-POST. After using it, we found CAM-POST to be very powerful and able to solve many complicated CNC machine applications.”
“I like CAM-POST’s ability to interface with our CAM systems and ease the development of each machine’s NC post-processors, while still being flexible enough to cater to the programming needs of each manufacturing engineer.”
Frank Moats Sr. NC Programmer GKN Aerospace-Chem-tronics Div.
“ICAM was suggested by SIEMENS when our Wotan machines with 840D controls were purchased. We chose to stay with the generic post we had been using, because we didn’t think that other post-processing solutions had anything more to offer. By delaying the purchase of ICAM’s post we hindered our use of the machines for the first 4 years we have owned them. We had limited use of CYCLES and tool length offsets among other features. The turning point was a visit to GKN St. Louis where the ICAM product is used extensively. Most impressive is ICAM’s DST 5-axis HS machines.”
“Now ICAM’s CAM-POST product allows us to program without including a preset tool length; we can use CYCLE statements in any head orientation. While the CYCLE implementation sounds minimal it is in effect huge, with the old method we had to create point to point drill cycles. Tapping at a compound angle wasn’t even considered, now it is easy. During swarf milling operations we were again hampered by preset tooling, backing the machine up to make a small adjustment was nearly impossible. Replacing a tool was an adventure, we use heat shrink holders, these are difficult to accurately preset. Frequently we had to repost for new tool lengths.”
“ICAM allows us to use the controllers’ TRAORI function which in turn allows us to do away with preset tooling. Small adjustments are easily done by adding to the wear offset in the controller. “
“We use CAM-POST to generate the NC code for the difficult surfacing involved with the (car) body work. We are currently using Mazak 4-axis vertical milling machines, and we have Mazak 3 and 4-axis lathes.”
“CAM-POST was set up so that we could change different variables, like table travel and maximum spindle speed, for example, to suit the different Mazak CNC machines.”
“We have been using CAM-POST for the past four years, and we have not needed to use any other post-processor, since CAM-POST is able to meet all our expectations.”