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required to manage the increasing complexity of the compo- nents involved, according to Childs. CAD data is readily imported into VISI in whatever format


the customer supplies it, whether it’s a STEP, IGES or Para- solid file. “We carry out various checks on the file to ensure its integrity, before laying it out in a way that can produce the component from the machine tool’s point of view. Ten we’ll assess the part’s machinability,” Childs explains. As part of that process Delta Tooling finds VISI Machining’s collision control and kinematic simulation extremely valuable. “Having made a major invest- ment in a new five-axis machine, the last thing we want is to cause a collision. We always run full-kinematic simulation prior to any production run.”


Automatic Toolpath Trimming A new feature in VISI 20, which


Childs says represents “a huge step forward” for them, is the dynamic incremental stock (DIS) command that automatically creates the stock model from the uncut material of previous toolpaths, to be used as reference data for subsequent milling operations. It au- tomatically trims the toolpath to remove unnecessary movements and fresh air cuts. “Tis allows us to machine rough from one side of the component. When we turn it over we have a new machin- ing cycle that allows us to rough again, but we’re not cutting fresh air” Childs notes. “Tis reduces machine cycle time further, making us even more efficient.” Having their roots in mold and


press toolmaking, Delta diversified into producing fully machined parts, honing their skills with critical components for a number of F1 sector customers and waveguide components for space satellites. “Te combination of our five- axis machines and fully integrated VISI CAD/CAM package means we can react extremely quickly to our customers’ demands—especially the motorsport industry,” says Childs. “For this reason, it is imperative that the [members of the] VISI support team are able to react equally as quickly and they have never let us down. It’s clear they understand our industry and our manu- facturing needs.” Te Mikron runs almost constantly across two shiſts from


8 am to 2 am the following morning, manufacturing to a call-off order for RSLSteeper on a monthly basis, as well as


machining components in additional production runs for Delta Tooling’s motorsport customers. “We’ve built a solid reputation based on our speciality of


producing complex parts with a very quick turnaround time, and a number of customers have been with us for several years. VISI has already helped us make our mark as a company in the three-axis marketplace and now the combination of the new five-axis Mikron machine tool and VISI five-axis machining is making us even more efficient and very competitive.”


Machining the aluminum knuckle for the bebionic3 at Delta Tooling. Te bebionic3 was unveiled in the US in September 2012,


and subsequently introduced to the UK at a London launch in November. It looks as if RSLSteeper’s design innovation along with VISI and Delta Tooling’s expertise will ensure the product’s future progression and manufacturing for a long time to come, maintaining RSLSteeper’s vision of improving amputees’ lives.


Edited by Yearbook Editor Michael C. Anderson from information supplied by Vero Software Group.


Medical Manufacturing 2013 53


Photo courtesy Vero Software


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