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Cavalier Tools and Manufacturing has saved time and money by switching to Delcam Electrode for the design and manufacture of its electrodes. The company has gone from outsourcing about $600,000 (£385,000) a year on EDM to pulling all that work back in house with a single OPS Ingersoll machine and Delcam’s software.

Cavalier Tools — based in Ontario, Canada — creates 200 or more moulds per year, most of which require multiple electrodes for their manufacture.

The company had wanted to expand and was aware that EDM was a long process that should have room for improvement. Looking to Delcam for a solution, Cavalier Tools decided to add an OPS Ingersoll machine and the Delcam Electrode software.

Key benefits of product application

  • According to Brian Bendig, president of Cavalier Tools, Delcam did a good job of working with OPS Ingersoll in Germany to construct a solution that simplified the EDM process.
  • Mark Langlois, EDM leader for Cavalier Tools, described the transition as being ‘like night and day’; before the Delcam software was added, the EDM process was long and drawn out, but now the company just takes data from Delcam Electrode directly to Ingersoll, so there’s no typing.
  • Delcam customised a few items inside the program menu to meet Cavalier Tools’ needs. Delcam was also able to work with OPS Ingersoll to create a custom script to streamline the programming of the machine’s operations.
  • Langlois explained that EDM was a long process, whereas now it’s just a couple of clicks; he can get his electrode with almost no work. Once the electrode design has been finalised, it can be put straight into Delcam’s Powermill CAM system for machining.
  • The savings that Cavalier Tools has made are said to be contributing to steep progress by the company; Bendig said that the company is roughly five or six times faster than before and that the increase in throughput has been high.
  • Bendig highlighted that the increased productivity from having Delcam Electrode and the OPS Ingersoll machine has paid for all the costs incurred from buying them.

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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