Aerospace parts that mix milling and turning raise the stakes for programming accuracy, schedule certainty, and operator confidence.
JR Machine faced increasing complexity and the practical limits of hand-tuned code on multitasking machines.
This story follows how the team reshaped its approach to programming, verification, and on-machine execution, and what that meant for day-to-day performance on the floor.
The lessons apply to any shop chasing high-tolerance work with limited time and headcount.
Client Snapshot
JR Machine is a leading contract manufacturer of complex, precision-machined parts serving the aerospace sector.
The company operates from Shawano, Wisconsin, and focuses on tight-tolerance work suited to multitasking CNCs.
With growing demand for complexity, the team prioritises consistent programming methods and clear communication to operators. Industry: Aerospace. Location: Shawano, WI.
The Challenge
Programming mill-turn aerospace parts was technically possible, yet the workflow created friction.
Programmers wrote workable CAM code, then repeatedly returned to hand-edit G-code, which stretched lead times and raised the chance of operator error.
One lead programmer found it easiest to write a mill program first, then tweak it for lathes, effectively doubling programming time while adding uncertainty on the floor.
A consistent method was needed to remove manual edits and give operators instructions that were easier to follow.
The Solution
JR Machine implemented Mastercam Mill-Turn to unify milling and turning in a single programming environment and job setup.
Parts that once needed separate lathe and mill operations now run on one multitasking CNC, reducing multiple setups, manual part handling, redundant fixturing, and downtime.
Productivity improves because the workflow is coordinated around the actual machine configuration.
Programmers rely on the included Simulation to verify toolpaths against a digital twin of the paired CNC.
Programs are loaded and watched in real time on a detailed virtual model of the machine, which cuts down on prove-out and last-minute code edits at the control.
The team also enabled Dynamic Turning.
These stock-aware toolpaths automatically adjust rotation speed, cutting angle, and tool depth to match conditions, helping control chips, protect tools and materials, and run faster with greater confidence.
For certain geometries, JR Machine uses 3 + 2 machining to harness multiaxis advantages in a 3-axis environment.
By tilting the tool to a fixed angle and indexing through orientations, programmers can mimic aspects of 5-axis without switching to full simultaneous multiaxis.
Results
JR Machine increased shop capability without buying new machines by upgrading CAD/CAM.
Programming time decreased, part quality improved, and operator execution became more consistent thanks to a single-setup Mill-Turn approach supported by Simulation and Dynamic Turning.
The highlights note that “Mill-Turn can increase machining efficiency by 100% in some cases.”
“Using Mastercam has really helped with training. Now, it’s much easier to get people up to speed. It’s hard to find experienced employees, so if Brock can program a part in the office and make it almost foolproof as it goes to the machine, it’s easier for an operator to comprehend what’s going on. The operator no longer has to massage the program or know exactly what every single line of code is doing.”
Shane Kunschke, Vice President of Manufacturing, JR Machine.
At a glance:
- Capability increased without hardware upgrades
- Programming time reduced and part quality improved
- Consistency improved through Simulation, Dynamic Turning, and 3 + 2 workflows
Why It Matters
Many shops face the same constraints as JR Machine – complex parts, limited headcount, and the need to do more with existing assets.
An integrated mill-turn workflow reduces setups, limits hand edits, and shortens prove-out, which frees operators to focus on making good parts.
For solution details, visit our Mastercam Mill-Turn page.
The Bottom Line
JR Machine’s experience shows how software-led changes can unlock more capability from the same machines.
With Mastercam Mill-Turn, integrated Simulation, Dynamic Turning, and 3 + 2 strategies, programmers deliver cleaner code and operators run with greater confidence.
To explore similar gains, contact the Mastercam team to review current workflows, book a tailored demo, or request a Mastercam trial.
Content adapted from the original case study published by Mastercam.
