CAD/CAM software is used to translate computer-aided design (CAD) to manufacturing workpieces with computer-aided manufacturing (CAM) on your CNC machines. Mastercam offers CAD/CAM software tools for a variety of CNC programming needs, from basic to complex. Due to its innovative, flexible solutions and top notch network of support, Mastercam software is a complete solution from the start of design through to manufacturing. It is the most widely used CAM brand globally. Machine Tools World interacts with David Boucher, Chief Product Officer, Mastercam to ascertain the dynamics of the CAM business worldwide, and the technological innovations spearheaded by this conglomerate to bring the best of technologies and machining practices to the metalworking and manufacturing world. Excerpts:
Q. You are a veteran in the CAM industry. Please brief us about your journey with Mastercam.
I have been involved in the CAM industry most of my working life. I started as a developer for a UK CAM start-up and progressed through various development, product, and management roles through the years. I started working with Mastercam in a consultancy role in 2008 and joined full-time in 2010 as Mill-Turn Product Manager before taking on the role of Product Director in 2012. I have held the position of Chief Product Officer since 2018, and in this role, I am responsible for the overall direction of the Mastercam product, working with a team of product managers and owners, as well as our global network of resellers, partners, and customers.
Q. What is the process involved in the development of new CAM technologies at your end?
New features are developed in two ways. First, our internal experts propose new ideas and concepts for programming based on emerging manufacturing trends. Second, we get feedback and suggestions directly from resellers, partners and customers.
As we refine these ideas, we test them at our in-house Manufacturing Lab. Our Lab is a fully equipped with machine shop that mixes the latest in machine tool technology with common “work-horse” machines so that we can test new ideas in various real-world shop conditions. We rotate the machines out of our shop on a 12- to 18-month cycle to help ensure we have a wide variety on which to test.
Once proven out, the software goes to our extensive Beta Testing community made up of Mastercam users across the globe that want to immediately use and dissect the latest CAM technology. That feedback goes through a final rigorous testing phase, with new refinements always available to Beta users for testing on the shop floor.
We are also fortunate to have a vast network of top-tier partners in all areas of manufacturing. With our close partnerships, we can see upcoming trends and develop software tools to ensure that users can run the hardware the optimal way the manufacturer intended.
Q. Tell us more about Mastercam’s focus and innovative approach to technology development.
Technology and platforms change quickly. We have built and maintained an unmatched global community by keeping a single focus while delivering that change. We push ourselves to produce methods of machining faster, more efficiently, and with more automation and precision.
Mastercam has introduced several pieces of technology to assist with this need in the last few years. Our Dynamic Motion Technology creates material-aware toolpaths, which keep a more consistent chip load on the tool while using more flute length. The result is safer cutting that is up to 75% faster for many parts.
Another innovation is a technique known as ‘Accelerated Finishing’. It delivers better 3D finishes in a much shorter time on certain sets of complex surfaces by using new shaped tools to their fullest potential. We work closely with tool manufacturers to develop toolpath motion that takes the most advantage of what can be done with these emerging tool shapes.
Q. How do you stand out in the competitive space?
Mastercam has more than 300,000 global installations, making it the most widely used CAM software brand according to independent research company CIMdata, inc. This gives us unmatched insight into the needs of machinists and lets us shop-test new and innovative techniques in more practical situations than any other CAM software.
Keeping in line with our original philosophy, we also have the largest number of global service and support organizations in the CAM industry; nearly 440. These local organizations provide Mastercam expertise to shops, help them with challenging manufacturing issues, and in many cases act as partners to help them get the most from their software and hardware.
We extend this view of partnerships to hardware and software producers across the industry. Our open architecture lets innovative developers create highly specialized programming tools that run directly within Mastercam. We work directly with equipment and machine tool manufacturers to make sure Mastercam users will be able to get every bit of benefit possible from that equipment, and we have close partnerships with the leading tooling manufacturers.
Q. What are the factors that helped Mastercam become successful in India?
Three critical components have helped make Mastercam successful in India:
First, we have forged a strong and wide-reaching sales and support organization in India to ensure Mastercam users will have the technical backing they need to succeed. Mastercam India brings decades of CAM expertise to a thriving industry. I have been there to work with them and hear first-hand the specific needs of the Indian market.
Second, we carefully watch the changing Indian manufacturing sectors, evaluate what specific applications they need to reach their goals, and provide focus in those areas.
Third, we continue to work with our Indian users as partners to gain insight into what they need to expand their current business, address new manufacturing applications, and improve day-to-day operation.
Q. Which are the areas of machining we see rapidly expanding?
Mastercam has a strong focus on advanced manufacturing applications. This includes growth areas such as high-end 3D work, multi-axis machining, and mill-turn machining. Reduced setups, broader scope of achievable work, and high precision – all help serve the expanding market, so we are developing ways to help push those techniques even further.
We regularly post resources for shops who are evaluating the benefits of these advanced techniques. An example is the information and tools we have about Multiaxis machining at(www.mastercam.com/multiaxis/). We encourage everyone to take a look.
Q. There is currently a skills gap to adequately staff the growing manufacturing market. Do you see that globally and what are your plans to help address that in India?
We do see this issue globally and therefore have strengthened our efforts to be at the forefront of Education market.
Mastercam proudly works with various organizations across the globe, such as Titans of CNC Academy, WorldSkills, MFG Day, FIRST Robotics, and our own Wildest Parts competition to make sure Mastercam is seen in our schools.
As far as addressing the skill gap in the India and Middle East region, Mastercam India proudly promotes our software to academia, with a current presence at over 1,000 educational institutes across the country.
In recent years Mastercam India have partnered with Tata Technologies to help upgrade technology, curriculum, and equipment across ITIs, Polytechnics and Engineering Colleges & Universities in the region. With the initial success of agreements with 4 state Governments, the consortium will be collectively upgrading close to 500 institutes, a third of which has already been deployed in the state of Karnataka. With over 3000 bundled licenses of Mastercam, around 20,000 highly skilled technicians will step into the manufacturing industry job-ready and with Mastercam knowledge.
Overall, the initiative will see close to 9,000 bundled licenses and close to 75,000 individuals each year who will carry the latest manufacturing and CAM knowledge into the industry. This will go a long way to filling the core manufacturing job vacancies in the country, providing opportunities for entrepreneurship, and addressing positions abroad that require reliable, certified, and knowledgeable manufacturing professionals.
Q. How is Mastercam working with and enabling newer technologies like IIoT, AI, ML and Industry 4.0/5.0 tools within Mastercam?
We focus on where Mastercam can accept and output information and how that data can be used and coordinated elsewhere in a shop’s process. Mastercam powers the machine tools, but that is just one part of what a shop needs to do. Mastercam also provides a platform for the shop to do various things like metrology, robotics, or digital tool management—all these pieces add to the growing connectivity of Industry 4.0.
Large manufacturers have already transitioned to smart manufacturing and Industry 4.0 over the last several years by expanding existing ERP/MES systems with cloud-based technologies, data mining, analysis, and other enterprise-wide systems. The level of potential efficiency improvements and productivity gains is both wide and deep for CNC programmers who have access to real-time data from the machine tool. These benefits can range from refining toolpath strategies to generating cost analysis studies, monitoring machine and operator performance, troubleshooting issues, or improving part setup and work holding conditions. Improvements in any one area can provide significant benefits, while increases across each can result in far greater value.
Now that Mastercam is part of the Sandvik network, we have exposure to a wide variety of deep manufacturing, tooling, and shop data that will help us better prepare shops for the broader use of new technologies.
Q. With seemingly everything moving to digital interaction, what is the value of having people still involved in business support?
At Mastercam, we view our global network of specialists as not only support in the business side of things but also as a partnership designed to help your shop work at its peak.
In addition, we understand the critical role of strong, local support and service. We are careful to ensure our local representatives are the experts in their fields and can help Mastercam users get the most from the software tools they use.
In the South Asia and Middle East perspective, our colleagues at Mastercam India have a wealth of experience in delivering and supporting CAM-centric solutions for close to 25 years. Mastercam India employs sales and technical staff that are spread across the length and breadth of the region, who collectively communicate in over 12 different languages and dialects. Mastercam India Application engineers are enriched with CAM experience and have a common goal to delight our customers.
