Producing complex molds requires precision, speed, and complete control over the machining process.
For The H-J Family of Companies, a global manufacturer of transformer components, conventional methods couldn’t keep up with growing product demands.
The team needed CAD/CAM software powerful enough to manage intricate designs while shortening production time without increasing labour.
Client Snapshot
Founded in 1969 and based in High Ridge, Missouri, The H-J Family of Companies supplies components for transformers, switchgear, and breakers worldwide, operating facilities in the U.S., China, and Mexico.
The company produces bushings, insulators, and other engineered products using machining, foundry, and epoxy-molding operations.
The Challenge
Creating the complex molds used for transformer parts required extensive manual finishing and polishing.
Producing only a few molds per year, H-J needed a more efficient way to design and cut patterns that supported both foundry and epoxy-casting processes.
As demand grew, the company sought flexible, high-performance software to build tools and molds faster, machine complex geometries safely, and maintain tight tolerances across every operation.
The Solution
To modernise production, H-J implemented Mastercam Mill along with Dynamic Motion and Productivity+ features.
With four seats of Mastercam supporting 20 machinists, the software became central to their mold-making operation.
How Mastercam improved workflow:
- OptiRough toolpaths remove large volumes of material quickly and safely.
- Dynamic Motion technology enables smoother tool engagement, boosting accuracy and tool life.
- Productivity+ integrates probing routines for automated part setup and verification.
Mastercam’s partnership with Harvey Performance Company further expanded toolpath options.
Integrating Harvey Tool and Helical Tool libraries gave H-J access to advanced carbide end mills and miniature tooling ideal for precision electrical components.
Results
By combining Mastercam’s CAD/CAM power with Harvey’s specialised tooling, H-J dramatically increased output.
The company now produces one mold per month instead of four per year – without a significant rise in labour.
Dynamic toolpaths like OptiRough, OptiRest, and Flowline handle large aluminum molds up to 14.5 inches in diameter and 5 feet tall.
Machinists rough and finish complex surfaces in 3-axis mode, even without 5-axis machines, achieving ± 0.002-inch tolerances.
“We’re making molds in 8 to 12 weeks, which sets us apart from a lot of mold shops and product manufacturers. We can now take and produce custom products, complete with tooling, in weeks as opposed to the better part of a year.”
Doug Goforth, Manufacturing Support and Improvement Manager, The H-J Family of Companies
Key benefits:
- Mold-making time cut from months to weeks.
- Complex molds completed in-house wiMastercam-machined transformer components – precision electrical parts manufactured with Mastercam technologythout outsourcing.
- Increased accuracy, productivity, and tool longevity.
Why It Matters
For manufacturers working with intricate geometries or tight deadlines, the right CAM software transforms capacity.
Mastercam combines precision and flexibility, allowing teams to use existing machines to deliver results once possible only on higher-end equipment.
Its Dynamic Motion toolpaths, simulation, and tooling partnerships help businesses like H-J achieve high-quality output faster and more safely.
The Bottom Line
The H-J Family of Companies proves that advanced CAM technology shortens mold cycles and expands machining capability.
With Mastercam, the company produces custom products in record time while maintaining the precision required in transformer manufacturing.
Contact MECAD Manufacturing to discuss how Mastercam can modernise your mold-making operations or schedule a personalised demo.
Content adapted from the original case study published by Mastercam.
