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FEATURE CAD/SOFTWARE I


n aerospace work involving both milling and turning operations, programming workflows can quickly become time consuming and


difficult to manage. Some programmers still rely heavily on manual edits to make programs work correctly across different machines, but this adds time to production and increases the risk of operator error. This approach becomes harder to sustain


as part geometries become more advanced and manufacturers face increasing pressure to improve consistency. To help address some of these challenges,


more integrated CAD/CAM workflows are simplifying the way complex parts are programmed and validated before they reach the machine. Rather than treating milling and turning as separate processes, manufacturers are increasingly bringing both together within a single workflow.


working efficiently Take mill-turn machining. Here, parts that previously required separate turning and milling operations can now often be completed on a single machining centre, helping reduce setup time, manual handling, and unnecessary movement between machines. For aerospace suppliers working with tight


tolerances and complex geometries, reducing setups can also help improve consistency throughout production. Fewer handoffs between machines means fewer opportunities for alignment issues or small variations that can affect part quality later in the process. Integrated CAD systems are also helping


manufacturers work more efficiently from the start. Accurate models can be created directly from customer drawings, complete with tolerances and surface finish requirements, allowing programming teams to move more smoothly from design into machining without losing important information between systems.


visualisation Simulation is also playing a larger role in day-to- day machining operations. Instead of relying on physical trial and error, programmers can now visualise the machining process before production


“Accurate models can be created directly from customer


drawings, complete with tolerances and surface finish


requirements, allowing programming teams to move more


smoothly from design into machining”


2


Stuart Adams, UK managing director at Mastercam, examines how more


integrated CAD/CAM workflows, simulation


technologies and digital twins are enabling aerospace suppliers to streamline the manufacturing process


begins, helping identify potential issues earlier in the workflow. Digital twin technology, meanwhile, enables manufacturers to test programs against a virtual representation of the machine itself. This becomes particularly valuable when machining high-value aerospace components where mistakes can be expensive and time consuming to correct. Furthermore, dynamic machining strategies


can automatically adjust cutting behaviour based on machining conditions, helping improve tool performance while maintaining safer and more stable cutting environments.


the workforce of the future Experienced machinists and programmers remain difficult to find, particularly for shops taking on more advanced aerospace work. As a result, manufacturers are looking for programming environments that make machining processes easier to understand and easier to repeat consistently across teams.


4 DESIGN SOLUTIONS SEPTEMBER 2026 More intuitive workflows, combined with


simulation and verification tools, can help reduce reliance on manual edits at the machine and make it easier for less experienced operators to work confidently with complex parts. Some manufacturers are also using


approaches such as 3+2 machining to expand capability without moving fully into multiaxis investment. By applying fixed-angle machining strategies within existing environments, shops can take on increasingly sophisticated work while continuing to maximise the value of their current equipment. For aerospace manufacturers, that flexibility


matters. Improving capability no longer depends entirely on adding new machines to the shop floor. Increasingly, competitive advantage comes from how effectively manufacturers program, simulate, and optimise the equipment they already have.


Mastercam www.mastercam.com


www.designsolutionsmag.co.uk Streamlining


aeroSpace partS manufacturing


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