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Powermill Robot brochure - .PDF file.

CNC Polystyrene makes large-scale models for scenery, in-store displays and special events for customers including Gap, Harvey Nicholls, Selfridges and Harrods. The company uses Powermill Robot from Delcam and an ABB640 robot, which enable it to produce bigger and better items while maintaining a high level of accuracy and consistency.

CNC Polystyrene undertook work on props used for the opening and closing ceremonies for the 2012 Olympics. Another unusual project saw the company producing a series of 2m-tall rabbits for the Ann Summers retail chain.

The ABB robot has a reach of up to 3.2m, allowing the company to create much larger pieces.

Derek Gibb, production manager at CNC Polystyrene, said: ‘We used to do a lot of work for TV and films where we were restricted by the size that we could produce in one piece. With the robot, we can go up to 2.5m high and almost 2m wide all the way around. We can create things much quicker in one piece, instead of having to make and assemble multiple pieces.’

Click on the link above to download the Powermill Robot brochure.

Key benefits of product application

  • Jeff Phillips, managing director at CNC Polystyrene, believes that Delcam’s software is the best in the industry. He said an important benefit of the software is that it ensures the robot can create genuinely identical products.
  • Powermill Robot allows CNC Polystyrene to see the program on the computer before actually cutting, which helps to reduce waste and so ensures that the company can offer its clients the best price for the project.
  • CNC Polystyrene can send video footage of the simulation to its customers so that they can see what the finished product will look like and, if required, make changes before any material is cut.
  • As well as giving users access to all the multi-axis machining strategies within Powermill, Powermill Robot allows numerous projects to be worked on at the same time, making the whole process a lot easier.
  • According to Gibb, whenever he has had to telephone the Delcam support team they have always been very helpful. If they couldn’t figure out the problem there and then, he would upload the files and they would then run it through on their software, see where the problem lay and provide a solution.
  • Phillips concluded: ‘Our clients want bigger and better models, and we have to be in that market. Without the robot and Delcam’s software, we would not have survived.’

Delcam supplies software and services that help manufacturing companies to maximise their profitability by increasing productivity, improving quality and reducing lead times. The company is the world's largest specialist supplier of computer-aided machining software, with its PowerMILL, FeatureCAM, Partmaker and ArtCAM programs making up the most comprehensive range of CAM systems from any developer.

This broad selection allows Delcam to offer a CAM system capable of machining virtually any product, in any material on any type of equipment. Delcam also develops product design, tooling design and quality control programs. The unique Tribrid Modelling approach to design incorporates solid modelling, surface modelling and triangle modelling in a single program, enabling complete design and reverse engineering projects to be undertaken without transferring data between software.

Delcam's Powerinspect offers fast, reliable comparison of parts, prototypes and tooling against CAD data on all types of inspection equipment and even on machine tools. This versatility has made it the world's leading hardware-independent inspection software. Related programs are available for checking machine tool set-up and part location. Delcam software is used in over 80 countries worldwide by around 40,000 organisations, from large multi-nationals to small sub-contractors, in industries including aerospace, automotive, dental, engineering, footwear, medical and toolmaking.

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