In the metals industry, speed and consistency define competitiveness.
As new equipment and orders multiplied, Tampa Bay Steel found its growth limited by disconnected software systems.
Each machine required a different CAM program, leaving skilled operators locked to single machines and creating costly downtime.
Leadership knew that to remain flexible and ready for the future, they needed a single intelligent platform capable of running every machine on the floor – and SigmaNEST became that solution.
Client Snapshot
Tampa Bay Steel, founded in 1980, has grown to operate a 220,000-square-foot warehouse with eight acres of outside storage and 125 employees.
They process flat and structural shapes in carbon steel, stainless steel and aluminium across a comprehensive machine park including lasers, water jets, HD plasma and flame cutting machines.
The Challenge
Tampa Bay Steel’s machine operations were hampered by software silos. Each cutting machine or process – laser, plasma, water-jet – used its own proprietary CAM programming package, so:
- A specialist programmer was required for each machine type, creating bottlenecks and machine idle time.
- New machines added to the facility risked further segmentation, as each would require its own dedicated software and training.
- Planning machine purchases with future growth in mind was limited by legacy software tied to specific vendors rather than flexible workflows.
With growth goals and a desire to avoid staffing increases, the firm needed a unified software platform that could span all equipment types and future-proof the machine park.
The Solution
Tampa Bay Steel selected SigmaNEST as the consolidated CAD/CAM and nesting solution across its entire cutting operations. Key solution components included:
- Standardised programming: Any estimator or programmer can now drive any machine type – laser, plasma, water-jet or flame.
- Machine-agnostic flexibility: “One of the reasons we chose SigmaNEST was because of future machine purchases. We didn’t want to be constrained to run each machine with its own proprietary software,” says Dave Carpenter, Engineering & Estimating Manager.
- Advanced bevel and water-jet workflows: With SigmaNEST v20’s enhanced bevelling capabilities, the team manages demanding water-jet parts with tight tolerances and reliable post-processor updates.
Results
“SigmaNEST has been hugely beneficial, as it’s allowed us to improve all areas of the manufacturing workflow, from quoting through to production. Our estimators are all using SigmaNEST, and can push jobs directly into production knowing the job will be programmed exactly as quoted.”
Dave Carpenter, Engineering & Estimating Manager, Tampa Bay Steel
Key outcomes:
- Programming bottlenecks and machine idle time were significantly reduced thanks to one CAM solution.
- Estimators push jobs straight into production, eliminating hand-offs and cutting lead times.
- When the new Mazak OptiPlex 3015 Fiber Laser was installed, SigmaNEST was operational on day one – no additional staff needed.
Why It Matters
For companies involved in metal fabrication and processing of flat or structural shapes, moving from machine-specific CAM to a unified platform like SigmaNEST delivers measurable benefits. By breaking down programming silos, manufacturers can:
- Adapt quickly to new machine types without adding licences or retraining staff.
- Synchronise estimating and production workflows for faster job turnarounds.
- Maximise utilisation by allowing any programmer to operate any machine.
The Bottom Line
Tampa Bay Steel’s transition to SigmaNEST turned a fragmented machine environment into a streamlined, scalable workflow.
Unified programming eliminated bottlenecks, simplified onboarding, and future-proofed the company’s cutting operations.
Contact MECAD Manufacturing today to discuss how SigmaNEST can unify your production floor and schedule a live demo.
Content adapted from the original case study published by SigmaNEST.
