In large-scale structural-steel manufacturing, a single mis-cut or missing part can derail a project, delay shipments and inflate costs.
Phenix Construction Technologies recognised that as part volumes grew and geometry complexity increased, the manual tools and spreadsheets they relied on were no longer sufficient.
Seeking a scalable solution to drive repeatable precision, they turned to SigmaNEST to unify their CAD/CAM and nesting processes across global operations.
Client Snapshot
Phenix Construction Technologies is a next-generation steel infrastructure company specialising in pre-engineered buildings (PEBs), bridges and structural frameworks for sectors including aviation, automotive, retail and government.
Operating out of a large Gujarat facility with a capacity of 72 000 metric tons annually and a workforce of over 700, the company has delivered more than 2 500 building projects globally.
The Challenge
Phenix produces complex assemblies where every beam, girder and fastener must drop-in at the installation site.
Manual tracking and Excel-based part quantification risked errors which could multiply across repeating assemblies.
As one senior draftsman explains: “So many elements come together when engineering steel structures on such a massive scale.
Each new variable or detail introduces the potential for error, and at our scale, the errors can multiply. For Phenix, SigmaNEST takes care of the CAD/CAM part of the process and significantly reduces that potential for error.”
Furthermore, the machine park was diverse – plasma cutters, oxy-fuel burners, a multiple profile cutter – and each machine required specialised programming.
The company needed a unified software platform to maximise material yield, reduce nesting time and future-proof new machine additions.
The Solution
Phenix selected SigmaNEST to manage the full nesting and manufacturing workflow. Key capabilities included:
- Library & import support – Engineers use the SigmaNEST shape library and import custom DWG or DXF files to standardise geometry.
- Auto-Nest & Auto-NC – Automated nesting and NC generation are applied by material thickness and machine type; optimising remnant use and reducing manual layout efforts.
- Machine-agnostic programming – A single software platform now programmes Messer and Boda plasma, oxy-fuel cutters and the HGG MPC 350 profile cutter.
- Tracking & reporting – The system automatically tracks how many parts are cut per work-order, replacing manual spreadsheets and improving accuracy.
Results
“We’ve been using SigmaNEST for a year and a half now, and right away we noticed an improvement in our nesting time and material savings.”
Dhaval Seler, Senior Draftsman, Phenix Construction Technologies
Key outcomes achieved:
- Reduced nesting time significantly and improved material utilisation via remnant nesting.
- Eliminated spreadsheet-based part tracking and improved accuracy across assemblies.
- Achieved a scalable CAD/CAM platform that supports future machine acquisitions without additional software or training.
Why It Matters
Firms engaged in pre-engineered building manufacturing and structural-steel fabrication face high volumes and tight tolerances.
By migrating to a single platform like SigmaNEST that spans CAD import, nesting, tracking and machine programming, organisations can reduce bottlenecks, eliminate manual errors and scale with agility.
The Bottom Line
Phenix Construction Technologies’ adoption of SigmaNEST converted risk-laden manual workflows into an automated, efficient manufacturing system.
With fewer errors, less waste and seamless scaling of machine integrations, the company gained stronger project control and faster delivery.
Contact MECAD Manufacturing to explore how SigmaNEST can transform your steel-fabrication workflow and schedule a live demo.
Content adapted from the original case study published by SigmaNEST.
