How hyperMILL Enhances Speed and Workmanship in Our Contract Manufacturing Services
Our ongoing push for improvement is deeply rooted in the cutting-edge technology and tools we leverage every day at Athena Manufacturing. One significant advancement has been our transition to hyperMILL to produce elegant and efficient CNC toolpaths for complex 5-axis components. This revolutionary software has immensely advanced the speed, precision, and workmanship of our precision machining services. Continue reading to learn more about how hyperMILL has leveled-up our capabilities and further secured our position as a leader in modern contract manufacturing.
How hyperMILL Levels Up Our Processes
hyperMILL is a computer-aided manufacturing (CAM) software that establishes CNC toolpaths for our 5-axis machines, producing components with complex geometries and features with unmatched accuracy and precision. Think of a toolpath like a route you select in Google Maps - there are many routes to your destination but few that are perfect for exactly how you want to travel. While the Athena Manufacturing team isn’t new to advanced CAM/CAD software systems, our switch to hyperMILL has truly been a game-changer.
Here are some of the direct benefits we’ve experienced since integrating hyperMILL:
Reduction of Third-Party Resources
hyperMILL is pioneering in the industry, particularly in eliminating the need for third-party processors to generate the toolpath instructions in G-code and M-code for each machine. This reduction of stops on the journey reduces delays and the potential for miscommunication between software and machines which can even result in the inadvertent and extremely costly crashing of the machine spindle into the workpiece or its tooling.
Specifically, hyperMILL removes the need for historically clunky and unreliable third-party crash detection software because toolpath simulation and crash detection is built-in. As a result, our team has significantly increased confidence that the toolpath programs sent to the shop floor will run, and run safely without crashes and other surprises that can impact timely delivery of products. Since implementing hyperMILL, we haven’t experienced a single milling spindle crash at Athena Manufacturing! Our team attributes this achievement to the software’s reliability and precision.
Superior Modeling for Faster, More Accurate Production
One of hyperMILL’s most powerful features is its extensive modeling capabilities. Just as we create CAD models for the parts we manufacture, hyperMILL enables us to create CAD models of our machines, tools, and tool holders. With these models seamlessly integrated into the software, our team can simulate the entire machining process accurately from start to finish. This efficient and reliable platform eliminates the need for second-guessing or manual adjustments, resulting in much more reliable performance to schedules..
This level of control is especially vital when working with complex 5-axis equipment like our new Spinner machine, which involves multiple axes, movements, and dependencies. hyperMILL’s ability to model the part along with the machine, spindle, and table ensures that all these components are synchronized for optimal performance.
Fully Modeled Toolpaths Eliminate Variability
One significant improvement we’ve seen with hyperMILL is the reduction in touch labor. Because the parts, tools, and machines are fully modeled, the programmed toolpath machines a good part first time with minimal editing by the machinist on the shop floor, and often completely eliminating the need for secondary processes like deburring and other handwork. These additional touch labor requirements are costly, wasteful and time-consuming, so by removing them we improve product quality while passing on savings to our customers.
Continuous Improvement of Legacy Parts
At Athena Manufacturing, continuous improvement is at the heart of everything we do, and hyperMILL is a key driver of that progress in our machining department. Our team regularly reviews toolpaths for parts that went into production years ago and reprograms them for the hyperMILL to improve product quality and production efficiency. By doing so, we’ve uncovered significant time and cost savings and often passing savings on to our customers.
A More Efficient Future with hyperMILL
By integrating hyperMILL into our precision machining services, Athena Manufacturing has elevated our ability to deliver exceptional results for our customers. This advanced software has produced palpable results, from faster turnaround times to cost savings, and enhanced quality, particularly on parts with tight profile tolerances. Thanks to hyperMILL, our team can efficiently manufacture even the most complex models, providing the precision and reliability our customers depend on.
At Athena Manufacturing, we’re eager to adopt new technologies that enhance our contract manufacturing services, from automated equipment to advanced software solutions that support our quoting, machining, and quality processes. Whether our customers require complex aerospace components or high-precision semiconductor devices, Athena is equipped to handle their unique challenges better than ever before.