By applying 2D and 3D off-line programming, a fast growing tooling and pattern maker was able to chop hectic two-day programming effort at the machine down to a simple, 2h programming job.

Even though it was very new to its SprutCAM 2D and 3D off-line programming system, fast growing tooling and pattern maker to the thermoforming industry Sterling Products of Bridgewater, UK, immediately chopped a hectic two-day programming job at the machine into a simple, program and run off cycle that took just two hours. In addition, the company no longer has to purchase or maintain expensive form cutters which also reduces costs and production lead times. It is very rare for a company to visit an open house or exhibition, see a demonstration of a product from cold and be so impressed that a director places an order on the spot for immediate delivery.

But that's what happened to Dave Pearson, managing director of Sprut Technology UK of Taunton, when Steve Riddle of Sterling Products turned up at XYZ Machine Tools Open House where the SprutCAM Expert Version 4 software was being demonstrated.

Confesses Riddle: 'We were struggling to keep up with demand, so I drove one junction down the M5 to the open house to look at the various technologies on show to see what was available that could help shorten our lead-times'.

'When I saw the demonstration of SprutCAM I was immediately impressed, and when I found out it could be in our works for just GBP 3,250 the deal was done.' Sterling Products employs 12 people to help it provide tooling and patterns for the thermoforming industry.

Typical end products range from plastic trays for cakes or chocolates in supermarkets through to food packaging.

Single patterns are machined from model board or resin for customer initial approval before the finished tool sets are produced in aluminium in batches that range between one and 12.

While tolerances do not tend to be severe at +0.1 mm they are very demanding for the level of surface finish that has to be maintained.

'Within days SprutCAM had a huge impact on our business,' says Riddle.

'With hindsight it makes our previous methods seem extremely onerous'.

'We used to receive DXF files, decipher them and program the milling machines manually'.

'SprutCAM has already saved us hours and hours of programming time and reduced the likelihood of costly errors, improved lead time and considerably improved our machine utilisation because we work directly from the customer's original surface model.' With over 1,000 users worldwide, SprutCAM offline programming software is ideally suited to pattern making, toolmaking and subcontract machining.

Starting at just GBP 1,295 for the 2, 2.1/2-D Machinist milling package, this includes 12 months telephone and Internet support.

The higher functionality 2D and 3D Expert package, as bought by Sterling Products, has full on-site training, 12 months telephone and Internet support, and can be installed for just GBP 3,250.

Both levels of system are available with a 30-day free-of-charge trial licence that allows potential users to experience the full system and see the benefits in their own working environment.

SprutCAM 3-D Expert Version 4 combines powerful 2D and 3D strategies, model feature recognition and surface analysis capability with high quality toolpath simulation.

In addition, it is now an accepted SolidWorks Solution Partner product.

This means that users can continue to design the CAD model and then update and apply existing toolpaths without having to switch between one application and another.

At the end of January, when the seat of SprutCAM Expert was commissioned at Sterling Products, the company wasted no time putting its new acquisition to work.

Confirms Riddle: 'It was so straightforward to use that we machined our first job the same afternoon.' Following further training from Sprut Technology UK, the company has become even more adept at manipulating its new cam system and has been able to generate additional savings for which Riddle outlines: 'We no longer have to purchase nor wait for delivery of form cutters'.

'With the new CAM system we simply make use of standard ballnose milling cutters and leave all the calculations to SprutCAM.