Delcam CAD/CAM Boosts Blatchford Orthotics Output

Delcam has revealed that its Orthomodel design and manufacturing software has enabled Blatchford to boost its orthotics output. The system has also allowed Blatchford to increase its quality and consistency, and so improve the quality of life for the people who rely on the company to provide the best treatment for their health-related problems.

David Bownes, production manager at the main orthotics manufacturing site in Sheffield, said: 'We first moved into CAD/CAM eight years ago. 'The aims were to reduce lead times, improve accuracy and, at the same time, offer our customers repeatability. 'Our main objective was to reduce the amount of time we spend hand carving so we could increase our productivity and improve our quality, while offering our technicians a better environment to work in. 'We heard about the Orthomodel system from our colleagues, who had previously used this type of software, and with that recommendation we decided to give it a try,' he added.

The software was trialled with a group of specialist orthotists before being considered for general introduction. After several months of trials, Blatchford moved into full production with the Delcam software in February 2009 following positive feedback from the technicians. An important part of the decision was the user interface for the Delcam software. Bownes said: 'We decided to re-skill our existing technicians rather than bringing in CAD/CAM engineers because we needed people that could recognise whether or not the finished product was correct.

'Even though they had little experience of computerised manufacturing, they found the Delcam software to be very user-friendly. 'The biggest benefits come when producing a series of orthotics as the patient moves along the clinical treatment path, for example, the progressive reduction of a problem after an accident or sports injury. 'It is much easier to adjust the existing data rather than constantly recasting designs from the patient's foot.

'It also avoids the storage issue with large numbers of casts,' he added. Bownes said: 'We have co-operated closely with Delcam staff to select the best cutting tools and machining strategies. 'In addition, we are happy to work with Delcam on new additions to the software to take it to the next level. 'The latest release offers more flexibility, for example, the ability to manipulate the foot shape in seconds. 'Also, some clinicians prefer to use the option of measurements using the system's data library of shapes and this can save time in the production process,' he added.

Delcam Unveils Integrated CAM For Solidworks

Delcam has launched its integrated CAM system for Solidworks at the Solidworks World 2010 exhibition in Anaheim, California. The initial version of Delcam for Solidworks includes the company's technology for drilling and two- through five-axis milling. The company said future releases will cover the full range of machining operations, including turning, mill-turn and wire EDM. Delcam for Solidworks combines the benefits associated with Delcam's Powermill and FeatureCAM CAM systems. It is based on Delcam's proven machining algorithms.

For example, the software will offer Powermill's speed of toolpath calculation plus strategies for high-speed machining, including trochoidal roughing, spiral finishing and Delcam's patented race-line machining technique. These strategies are claimed to ensure increased productivity, maximum tool life and immaculate surface finish, even when cutting challenging materials. At the same time, Delcam for Solidworks will have the same focus on ease-of-use as FeatureCAM, including all of the knowledge-based automation. The software will include FeatureCAM's automatic feature recognition system, which automatically extracts detailed feature information from the Solidworks model.

The system recognises holes and pockets within the model and groups similar holes by size and type automatically. It indentifies all the detail within the model, such as draft on pocket walls and any fillets or chamfers within the pocket. Once the features have been identified, Delcam for Solidworks undertakes automatic selection of cutting tools, machining strategies, and feeds and speeds, to complete the programming operation. Delcam for Solidworks will be fully integrated into the Solidworks environment so that the program looks and behaves like Solidworks.

It will offer full associativity so that any changes in the CAD model will be reflected automatically in the toolpaths. Delcam for Solidworks will not simply modify existing toolpaths but will also review the choice of cutting tools and machining strategies, and change them if necessary. All toolpaths generated with Delcam for Solidworks can be checked by the integrated simulation module on the computer before being passed to the machine tool. Finally, the software comes with Delcam's full range of post-processors to allow fast and accurate data transfer to all leading types of machining equipment.