Mould and die maker says offline programming system takes design data in various formats and helps the company to respond quickly to any programming demand and get the job up and running.

Although EDM Precision Engineering invested in Pathtrace's EdgeCAM offline programming almost seven years ago, such has been the pace of development of the software that the system is still keeping the Nottingham-based precision toolmaker ahead of the competition in terms of the 3D programming and CNC machining of complex mould tools and electrodes. Indeed, it was the promise of on-going product development and support that were among the main reasons for the purchase of EdgeCAM, from Pathtrace Engineering Systems of Reading, as managing director, Gary Skrzypkowski, recalls: 'We wanted a system which could be upgraded to meet the ever-changing demands we face, and we needed a supplier that would continue to provide high level back-up.' He maintains: 'Pathtrace and EdgeCAM have certainly lived-up to expectations and following a continual combination of developments, improvements and new features, as well as a high level of support and technical back-up, the system is right up to date and kept us ahead of the game. Product complexity has increased considerably over the years and this has been more than matched by regular upgrades in EdgeCAM's programming and prove-out routines.

Despite this increase in complexity of the type of work we handle, on average, we still only spend about a tenth of actual machining time on program creation.' Established in 1990 and employing 12 people, EDM Precision specialises in the manufacture of plastics injection mould tools which account for around 80 per cent of the business, with the balance generated from tool repair and modifications.

Both development and production type tools are produced and key market sectors served include DIY, domestic appliances, automotive components and cosmetics.

Tool specification ranges from single impression up to multi-cavity and composite tooling and can weigh up to two tonnes.

The Blidworth company produces at least one of these highly complex tools every three to four weeks and with all the electrodes and various elements required for each tool, extensive use of EdgeCAM means the generation of more than 100 new part programs every month.

Almost 90 per cent are long 3D programs which take 10 hours or more to run on its CNC machines.

Machining is based mainly on two vertical machining centres, a pair of wire electro-discharge machines and CNC vertical spark erosion machines.

The company has three EdgeCAM seats, two being DNC linked for 3D surface machining on the machining centres, and one for four-axis wire erosion and 2D milling.

As most customers now email 3D solid models of the component, this data is then used to generate cutter paths which means the process is simple and quick through the automatic capabilities of EdgeCAM.

Because EdgeCAM combines the expertise of mould and die with production machining, it allows the company to effectively use efficient 2-D prismatic and 3-D surface machining processes needed to machine cavities, cores, bolsters and electrodes.

Says Gary Skrzypkowski: 'The system enables us to accept design data in various formats and to quickly respond to any programming demand to get the job up and running as soon as possible.

This helps shorten development cycles and combats long lead times on complex work.

Program prove-out has also been optimised as it now takes us less than half the time we used to spend five years ago to verify complex 3D cutter paths.

Because we can quickly eliminate the possibility of gouging, collisions or jam-ups on the CNC machines, our confidence in program integrity has considerably boosted productivity.' Although some hard machining is carried out, most cavities are semi-finish milled leaving around 0.1mm for removal by solid sink erosion.

The company reckons that generally this is the most productive and cost-effective method of creating 3D forms, particularly as a large number of customers specify a matt finish on the tool.

This is produced by vertical EDM.

However, when it came to producing a series of multiple tapered ribs for the handle of a new paint spray gun, wire erosion was the only practical option due to the complex profile, tight radii and blends and the varying heights of the forms involved.

Most of the graphite electrodes tend to be milled, though some copper electrodes are wire-cut which is an ideal process for producing rib electrodes with deep profiles.

Without doubt, Gary Skrzypkowski maintains that EdgeCAM has played a key role in improving the company's response time.

For example, the production of a development tool for a new style of washing machine bracket, direct from supplied CAD data, was a particularly urgent project.

EDM Precision produced and delivered the moulds within 10 days.

In another case, a special aluminium injection mould tool was designed, developed and delivered within 14 days.

He says: 'Such speed of turn around is critical as 15 per cent of our injection mould work tends to be for development tooling and, in most cases, is usually required in double-quick time!' 'When we look at today's demands, we definitely made the right decision in buying EdgeCAM,' sums up Gary Skrzypkowski.

'The system continues to be improved and updated, it keeps us at the forefront of CAM developments and we always receive good service and technical back-up.

We are also well in-touch with software improvements because Pathtrace runs Open Days each year to introduce new features and to gain user feed-back.