Avans Machine Inc. never tells a customer “no”. One day they are machining an aerospace prototype, the next day a medical fixture.
Every job brings new geometry that must run on one of forty CNC machines, from nine‑axis mill‑turn centres to wire EDMs.
Their previous mix of CAM software could not keep up, so the team went looking for a single system that could.
1. The Challenges Avans Faced
1.1. Mixed Materials and Complex Shapes
The shop cuts stainless steel, aluminium, plastics and tough alloys such as Inconel. Each material demands its own strategy and swapping between different CAM tools cost time and money.
1.2. Collision Checks by Hand
Without reliable simulation, programmers had to prove out code at the machine. Every dry run used spindle time that should have gone to production.
1.3. Bottlenecks on Nine‑Axis Parts
Custom posts and limited toolpaths slowed delivery whenever a complex component reached the nine‑axis mill‑turns.
2. Why Avans Chose Mastercam
Huntsville‑based CAD/CAM Solutions recommended Mastercam because it covered every machine on the floor and was easy to learn. Three points sealed the decision:
- Powerful Toolpaths – Dynamic Motion strategies such as OptiRough clear stock quickly while protecting the cutter.
- Built‑in Verification – Backplot, Verify and full Machine Simulation reveal clashes long before a programme reaches the controller.
- Nearby Support – CAD/CAM Solutions can visit the shop in under an hour and also runs hands‑on classes.
3. How Mastercam Improved Daily Work
3.1. Faster Roughing with OptiRough
OptiRough uses smooth, bi‑directional cuts and deeper step‑downs to remove material quickly and extend tool life.
3.2. Errors Spotted Before They Cost Money
Backplot shows tool motion as it happens. Verify highlights any clash between the tool, holder and workpiece. Programmer Adam Wright likes “making adjustments while I watch the simulation”.
3.3. Accurate Machine Simulation
Full kinematic models of the nine‑axis machines show axis limits and fixturing conflicts on screen. Crashes are prevented rather than repaired.
3.4. Automation That Scales
Reusable operation families, standard tool libraries and batch post‑processing let programmers turn out code for repeat parts in record time.
3.5. A Short Learning Curve
Mastercam “thinks like a machinist”, so even first‑time users were productive after brief classroom training, and help is only a phone call away.
4. The Results: Faster, Safer Production
| Benefit | Impact at Avans |
| Roughing time | Cut significantly thanks to OptiRough |
| Scrap and re‑work | Reduced because Verify and Backplot catch issues early |
| Tool life | Longer service life lowers consumable spend |
| Programming speed | Automation keeps forty machines supplied with code |
“We machine everything from stainless and aluminium to plastics and Inconels. We do not shy away from anything.” – Trevor Hall, CNC Programmer
5. The Bottom Line
The right CAM platform turns complexity into opportunity.
By standardising on Mastercam, Avans Machine Inc. can programme any material with confidence, trust every toolpath and deliver quality parts on the first attempt.
This content is adapted from the original customer story on Mastercam’s website.
