Process automation
The challenge of manufacturing custom patio glazing is to create efficient and error-free CNC programs for components with varying dimensions and configurations according to customer requirements. This blog will discuss how to move from manual programming to a process that extends from the sales phase directly into production.
The process is based on parametric design, which allows geometries to be edited without manual redrawing. When this is combined with CPQ (Configure, Price, Quote) systems, customer selections can be automatically converted into accurate production data. Post-processors play a critical role in converting this information into machine-specific code, and their customisation is therefore vital for production scalability.
In the future, AI and machine learning will make the process even more efficient, automating even the optimisation of machining paths and even enabling predictive maintenance.
CNC machining basics and customer orientation requirements
CNC (Computer Numerical Control) machining is a manufacturing process that uses the numerical values of a component to control the movements of machine tools, allowing the production of highly accurate and complex components. The process begins with computer-aided design (CAD), which creates a digital model of the product. Computer-aided manufacturing (CAM) software then generates the machining paths from the CAD model, which are converted to G-code and transferred to the CNC machine.
Although CNC technology revolutionised traditional manufacturing by bringing high precision and automation, its traditional applications are often designed for mass production. However, customers for patio glass products are demanding customised solutions, such as individual patio glass units and balustrades. This poses a challenge to traditional CNC programming, as constantly changing dimensions and configurations require manual editing or creation of programs, which is time-consuming and prone to errors. Enabling efficient and customer-oriented production requires a process that automates the entire workflow from sales to the CNC machine.
Concept from sales to production
The process starts in sales, where customer requirements are defined and translated into information that can be used in production. At the heart of this process are the CPQ (Configure, Price, Quote) systems, which act as sales configurators. These systems automate the quotation process for complex product versions, reducing it from days to minutes. The CPQ system allows salespeople to configure products according to customer needs and calculate the price in real time, while reducing the technical skills required to quote a complex product.
The system visualises the product for the customer, ensuring that the final product meets expectations, and automatically generates an accurate quote. The CPQ system often integrates with other business systems, such as CRM (Customer Relationship Management) and ERP (Enterprise Resource Planning), to streamline the entire sales process and order processing.
The following table shows a simplified digital workflow from sales to production, highlighting the communication between the CPQ system and other key technologies.
Simplified workflow from sales to CNC machine
| Stage | Process | System | Added value |
|---|---|---|---|
| 1. Sales & configuration | The customer determines the choices and dimensions of the product. | Product Configurator (CPQ system) | A fast, visual bidding process. |
| 2. Design automation | The CPQ system automatically generates a parametric 3D CAD model. | Parametric 3D model | Eliminates the need for manual drawing. |
| 3. CAM programming | The CAM software automatically creates the machining paths from the CAD model. | CAM software | Shorten programming time and reduce errors. |
| 4. CNC machining | The post-processor converts the machining paths into machine-specific G-code. | CNC post-processor | Allows the production of variable geometry. |
Parametric modelling and design automation
The basis for automating CNC programming in customer-oriented production is parametric modelling. It is based on creating CAD models whose geometry is controlled by rules and parameters. Instead of the designer drawing each individual part or assembly manually, the parametric model changes automatically when its defining values, such as length or width, are altered. A dimension or geometric relationship can be stored as an editable value, allowing the model to be dynamically modified.
The parametric model is crucial in the production of patio glass, where the customer can change the width of the railing or the position of the lock, for example, at any time. Parametric modelling allows such changes to be made quickly and accurately, as the designer does not have to redraw the model from scratch. Parametric modelling is at the heart of design automation, creating rule-based algorithms that automatically generate product models based on customer input.
The manual process of transferring customer measurements from a salesperson to a designer by phone or email is prone to errors and bottlenecks. Each step of data transfer slows down the process and increases the risk of error. By automatically generating a parametric CAD model, the CPQ system creates an instant and error-free link between sales and design. This transition changes the nature of the business from reactive (customer requests, we make) to proactive (customer configures, we produce). Competitive advantage no longer comes only from the skills of individual CNC operators, but from the speed and reliability of the entire production chain.
CAM software and its functionality
CAM (Computer-Aided Manufacturing) software is the core of CNC programming, which converts the geometry of CAD models into machining paths that the machine tool can understand. The CAM software defines, among other things, the tools to be used and the machining parameters, such as cutting speed and rapid blade movements. This process can be used to produce complex, high-quality parts that would not be possible using manual methods.
There are several leading CAM solutions on the market. Mastercam is the world’s most widely used CAM software, also available as an add-on for SolidWorks.5 PowerMill is a CAM software developed by Autodesk, especially suited for high-speed, 5-axis machining.5 AlphaCAM is an intelligent CAM software designed for wood, metal and stone machining. Integrated software, where CAD and CAM software are closely linked (e.g. SolidCAM integrated with SolidWorks ), is vital. It eliminates the manual steps of data transfer and allows automatic updating of the parametric model in the CAM environment as soon as dimensions change.
In automated workflows, customer inputs in the CPQ system directly drive the selection of machining strategies and parameters in the CAM software. These systems can even combine multiple orders into a production batch to minimise material wastage. This automation eliminates the need for customer-specific design work, where designers have to perform repetitive tasks to configure existing products. The CPQ system automatically generates CAD files and material lists directly for design or production.
Post-processor as a critical link in the CNC workflow
The post-processor acts as a customised software link that converts the neutral machining paths generated by the CAM software into machine-specific G-code. Its job is to adapt the program to the CNC machine being used.
In customer-driven production, where the geometry to be machined is constantly changing, customisation of post-processors is vital. Unique products with dynamic dimensions and holes at different points require the ability of the post-processor to handle these variables and generate the corresponding G-code automatically.
A parametric post-processor can include calculation equations that read the coordinates of the workpiece directly from system variables during program execution, eliminating the need to calculate and enter new coordinates into the CAM software after each change. The CAM model contains subroutines, or macros, which are called into the program and their position is changed according to parameters entered in the CPQ system.
In the traditional model, the post-processor is static and modifying it requires deep technical knowledge and is often time-consuming. This can lead to production downtime while waiting for new programs. The basis of automated workflow is that the post-processor is a dynamic tool designed to support parametric geometry. Investing in its customisation and simulation enables mass customisation and creates a competitive advantage for the company.
Benefits and challenges of an automated process
An integrated digital workflow brings significant benefits to manufacturing. The first is efficiency and speed. CPQ systems reduce the quoting process from weeks or days to minutes. Design automation then eliminates manual custom design, and CAM software creates machining paths instantly. This speeds up the overall lead time and improves the customer experience with fast quotes and delivery.
Another major benefit is accuracy and quality. By automating data processing instead of manual intermediate steps, digital workflow reduces the risk of human error. Errors in manual data copying and G-code writing can lead to production breakdowns and defective products.
The third benefit is the efficient use of materials. The system can optimise material usage by batch optimisation, combining multiple orders to optimise profile usage and reduce material wastage. Nesting software, which is part of CAD/CAM systems, optimises the layout of parts on sheets, saving material and reducing costs.
Creating an automated process requires upfront capital. CNC machines and associated software such as CPQ, CAD and CAM systems require capital, which can be a major barrier, especially for smaller companies.
Another critical challenge is the need for skills and resistance to technology. Traditional manual CNC programming and machine operation skills are being replaced by system skills and digital workflow management. This lack of skills can be a major bottleneck. Employee resistance to adopting new technologies is also common, and requires careful training and change management.
The third challenge relates to integration and security. Moving from disparate systems to a single integrated network makes the flow of information more efficient, but at the same time creates new security risks if the architecture of the system is not well designed. In addition, the seamless integration of different systems, such as ERP and CAM software, can be technically complex and require expertise.
CAM for the future
Artificial intelligence (AI) is the next step in the evolution of CNC programming, taking automation to a new level. AI-based CAM software can automatically generate machining paths and optimise parameters, taking into account the requirements of tools, fixtures and machine tools. The technology significantly speeds up quoting and programming.
Machine learning (ML) can also be used for real-time process optimisation. Sensors collect data on spindle speed, feed rate, tool forces and wear. AI algorithms analyse this data and adjust machining parameters on the fly, maximising efficiency, improving accuracy and extending tool life.
In addition, AI enables predictive maintenance. It can analyse machine performance data, such as vibration and temperature, and predict potential faults before they cause production downtime. This predictive approach reduces unexpected downtime and associated costs.
