Laser manufacturer makes major savings with 5-axis CAM software to supply formed metal and plastics components predominantly to the automotive industry for clients such as Ford, Toyota and GMH.
CAM software brings major savings to laser user
Laser manufacturer makes major savings with 5-axis CAM software to supply formed metal and plastics components predominantly to the automotive industry for clients such as Ford, Toyota and GMH.
Laser 3D, based in Melbourne, Australia, was established in 1992, supplying formed metal and plastics components predominantly to the automotive industry for clients such as Ford, Toyota and GMH.
During its rapid growth Laser 3D installed 13 laser cutting systems across two job shops giving the ability to provide a broad range of laser cutting and welding services.
With an expanding array of laser cutting machines for their increasing metal cutting requirements Laser 3D had to deal with the issue of programming them effectively.
Said Brian Finn, managing director "We were looking for possible ways to improve our response time and accuracy for 5-axis laser cutting.
Our initial programming on the LaserLab systems was by teaching.
The production of fixtures was slow, and programs were not accurate enough and it wasted machine time.
We subsequently selected PEPS SolidCut Laser for the 5 axis programming as it was capable of programming both the Laser Lab and Trumpf machines.
Other systems we looked at either could not program both machines or did not utilise circular interpolation in the NC code so the programs were very long and simple modifications to the program at the machine were not practical".
Finn continued: "PEPS also runs on low-cost hardware.
After installation there were huge time savings in the design and building of fixtures.
Setting up programs generated by PEPS at the machine took 50% less time than manual teaching.
Accuracy was also increased, however the biggest improvement was seen because of the utilization by PEPS of circular interpolation and the machine's built-in macros for holes, slots, etc.
It can automatically identify and profile 3D component boundaries and apertures, and with appropriate technology settings.
The programmer can use the system to automatically identify standard shapes supported by the post processor and output the CNC code using the canned cycles of the machine tool.
Many jobs can be programmed in seconds with very few clicks of the mouse.
Collision checking further reduces the possibility of error, with a full simulation showing the head and pipe positions.
Fixturing also saw a massive 80% time saving.
Laser 3D is using a high-end CAD system for much of their 3D development work, with completed components transferred into PEPS SolidCut Laser to apply cutting paths, run simulations and generate NC code.
PEPS is capable to take in CAD data using the wide range of CAD translators.
Training was provided by local agent Camtek Pacific.
Of the training Finn said: "Training from the agent was good and we also found the built-in training samples worked well.
Every user has unique requirements, and therefore a system needs to be able to accomodate those needs.
Commented Finn: "The system is really open to customisation.
We have requested a modification to the post output and it was implemented within a few days.
The support overall was and is excellent.
There are ongoing plans to expand Laser 3D's existing plant, and PEPS is an integral part of that plan.
Finn concluded: "Our Trumpf laser cell, three Laser Lab 5 Axis Pentacon machines and other equipment works in conjunction with PEPS SolidCut Laser, allowing us to meet tough deadlines.
We can deliver finished products with a greater level of accuracy as cutting is performed using design data direct, substantially eliminating human factor.
The major advantage of SolidCut is that it allows us to run an existing job on any available 5 Axis machine using correspondent machine geometry, configuration and post processor.
Also, we are not tied to any one machine manufacturer in the future as the PEPS machine library covers practically all existing multi axis laser cutting machines.
" We are now looking to use PEPS to drive our 2-axis laser machines.
Benefits achieved: - Ability to program different machines with a single system on low-cost hardware - Set-up and programming time reduced by 50% - Fixturing time reduced by 80% - Can import CAD files in a variety of formats due to CAD translators - PEPS uses the machine's built-in macros for holes/slots - Automatic collision checking and simulation further reduces the possibility of error - Excellent local support with several significant software updates from vendor.