CNC Programming
Computer numerical control (CNC) systems have been part of the manufacturing process for decades. Of course, modern CNC systems are highly automated and use electronic controls for more precise and predictable results than early punch card and paper-tape-based systems. Today’s systems can also use advanced forms of machining to produce parts from virtually any kind of material.
Still, the basic concept remains the same. A CNC machine uses commands to control a drive/motion system that moves various tools, including drills, lathes and milling tools. The tools and workpiece can move along multiple axes at varying speeds so that the material achieves the desired shape. A feedback system monitors the output and corrects any deviation from the input commands.
G-code is the most widely used programming language for CNC machines. The instructions in the G-code program define the tool path and tell the motors where and how fast to move.
Benefits and Challenges Of CNC Programming
The primary benefits of CNC systems are speed and cost savings. Parts once machined by hand can be produced faster and more efficiently. The process results in little to no waste, further reducing production costs. CNC systems also enable the automated production of more complex parts with greater accuracy. That’s why they are used in a wide range of industries, from aerospace and transportation to medical and electronics.
As manufacturers adopt more advanced and complex CNC systems, they are facing a shortage of qualified personnel with the ability to program them. Manufacturing companies find themselves with a work package from a customer, and they don't have the capacity to program it and get it onto the shop floor.
Some manufacturers lack the staff resources to use their CNC machines to their full potential, and may turn away valuable business because there’s no one capable of programming the machines to produce complex parts. By outsourcing or contract CNC programming, manufacturers can maximize the value of their investments and keep production schedules on track.
Capabilities
Saratech’s Contract CNC Programming and Postprocessing Services
Saratech offers high-end Contract CNC programming services to meet the most demanding requirements. We have assembled a team of programmers who have expertise with a wide range of CNC systems and environments. They can handle motion control, open- and closed-loop controls, power drives and positioning systems in two-, three and five-axis milling machines. Our team works in close collaboration with the customer’s engineers and manufacturing staff to ensure that the delivered program meets all specifications and requirements. We provide setup sheets, tooling lists and other documentation as required.
We also offer postprocessor development, translating the tool path defined within the CAM software into code that the particular CNC machine can use and interpret. Our postprocessors enable customers to get the most utility from both their engineering software and the CNC machine. We also maintain and update postprocessors as customers add new tools, processes and capabilities in their shop.
Saratech’s Simulation Services
Most CAM software can simulate a tool path in some rough form as it's running. However, the simulation is based on the generic tool path, not the information in the postprocessor. Manufacturers sometimes use third-party software to simulate the tool path as it's defined into G-code for the CNC machine.
Saratech utilizes Siemens NX Design Simulation to analyze the defined tool path, eliminating the need to modify the G-code when problems are identified on the shop floor. NX simulates the CNC process in real time using the actual constraints for the particular CNC machine.
We perform simulations at every stage of the process, from initial G-code development through postprocessing. The machinist who receives G-code from Saratech can rest assured that it will perform optimally because it has been simulated with the same capabilities and constraints as the tools on the shop floor.
Why Choose Saratech for Contract CNC Programming Services
Saratech has developed a proven methodology for delivering CNC programs that are precisely tailored to the customer’s needs. Our experts start by understanding any constraints in the customer’s design capabilities, machine tools and controls. This helps ensure that the CNC program integrates properly into the customer’s environment and can be used without modification. It also ensures the CNC machine is used efficiently for profitable production.
Our postprocessor development and simulation services further optimize the process. Often, complex parts require hours, days or even weeks of runtime on the CNC machine. Organizations are reluctant to send a program to the machine unless they are confident that the part won’t be destroyed by an inadvertent move. Saratech offers peace of mind that the process will be successful.
We also collaborate closely with the customer’s team throughout the project. We are focused on customer service and rigorous project management, providing real-time status updates and responsive support. Our goal is to serve as an extension of the customer’s team.
Contact Saratech for Your CNC Programming Needs
The Saratech team has experience with leading CNC systems and can support all machining methods. We can apply our services to a wide range of processes and materials, going beyond industry and manufacturer standards to meet the strictest requirements.
Saratech provides support for projects of any size, from full-scale production to rapid prototyping. We can effectively scale our project team to meet the customer’s requirements and project timeline. Whether the customer requires assistance with a highly complex project or simply some extra help with a heavy workload, Saratech can deliver.