When tolerances shrink and geometries grow complex, every cut decision matters.
This Mastercam case study explores how an aerospace specialist protects margins and delivery confidence by tightening control over toolpaths, verification, and fixturing choices across multiaxis equipment.
The focus is on stabilising chip load, protecting tools and stock, and keeping first-article risk low even on priority parts and difficult materials.
Client Snapshot
FK Instrument Co is a Clearwater, Florida aerospace manufacturer specialising in parts with exceptionally tight tolerances.
The operation runs advanced multiaxis equipment and high-mix work, where setup discipline and programming quality materially affect throughput.
A recent addition to the cell is a Yasda YBM 8T-TT paired with a Fastems 18-pallet system, capable of 5-axis conical machining circularity tolerance of 2.8 µm.
The Challenge
Producing ultra-critical aerospace parts under tight timelines left little room for manual trial-and-error.
Tooling options were constrained by part size and tolerances, making it difficult to maintain chip load without inducing vibration, heat concentration, or premature wear.
The team needed a programming approach that could balance stock awareness, stable engagement, and safe clearances while preserving spindle time for priority work.
The Solution
The shop standardised programming and verification in Mastercam, centring work around solid models and unified multiaxis toolpaths.
Programmers use Multiaxis strategies alongside Mill 3D, Lathe, and Wire, with Verify, Backplot, and in-system Simulation applied to identify collisions, gouges, air-cuts, and setup issues before a single chip is made.
Dynamic Motion toolpaths and Dynamic OptiRough in particular allow deep step-downs with stock awareness, minimising stepovers and engaging more flute length to spread heat and even out wear.
The result is consistent chip load on high-temperature, low-torque alloys and calmer, faster roughing that sets up finishing to hit spec.
Tools and tactics applied
- Unified Multiaxis toolpath access for Morph, Parallel, Along Curve, and Project Curve.
- Dynamic Motion and Dynamic OptiRough to keep engagement stable in frangible or difficult metals.
- A shared, fully customisable Tool Library to track cutters, holders, feeds, speeds, and fixture data across machines.
Results
Cycle-time reductions on priority parts, calmer cuts, and predictable tool life followed from stock-aware roughing and better verification.
Operators report consistent chip load, less vibration, and higher feeds and speeds on demanding alloys, while simulation and Verify/Backplot provide confidence for first-article runs.
The approach supports the company’s mandate to produce ultra-critical tolerance parts quickly and accurately.
“Dynamic OptiRough allows us to use higher feeds and speeds on the high-temperature, low-torque alloys we cut.”
Jeremy Fritchy, Manufacturing Engineer at FKI
Why It Matters
Many aerospace and high-mix manufacturers face similar constraints: tight tolerances, unforgiving materials, and pressure to move priority parts faster.
A model-driven, multiaxis workflow with stock-aware roughing and shared libraries offers a practical way to protect tools, reduce air-cuts, and shorten cycles without gambling on the machine.
For solution details, visit our Mastercam page.
The Bottom Line
FK Instrument Co demonstrates how tightening control over toolpaths, verification, and tooling data can lift speed and reliability on ultra-critical aerospace work.
Mastercam’s Multiaxis strategies, Dynamic OptiRough, and in-system verification help stabilise engagement, safeguard stock, and keep first-article risk low.
For teams aiming to achieve similar control on complex geometries and difficult alloys, consider a structured evaluation.
Ready to explore Mastercam for multiaxis precision? Book a demo or contact the sales team to review machines, materials, and rollout options.
Content adapted from the original case study published by Mastercam.
