Kormachine Delivers Complex Aerospace Parts

Kormachine is a fifth-generation manufacturing firm in Waco, Texas. The AS9100-certified company uses the latest equipment and technology, including Mastercam, to create products for discerning customers in industries such as aerospace, railway, automotive, and oil and gas.

QUICK FACTS


Product Used:

Lathe, Mill, Multiaxis, Dynamic Motion


Industry:

Aerospace & Defense, Energy, Transportation, Job Shop

Colter Kaspar

PROJECT DETAILS


When an aerospace company delivered a part that needed to be reverse engineered to Waco, Texas-based Kormachine, owner/operator Colter Kaspar received no accompanying print, no solid model. The customer wanted to take an extension off the part and then build a new one from scratch. The proprietary part measured 3 feet x 3 feet x 1 foot, consisting of a combination of Inconel, aluminum, stainless, and some copper brazing. Tolerances were a tight +/- 0.005 of an inch.

The Kormachine team worked together to reverse the dimensions, pulling them off as best they could because the original part was warped and cracked—bent and distressed in some places. They built the part from the ground up, drafting a new solid model, verifying it, and sending it out for approvals.

“The nice thing about creating a solid model in SOLIDWORKS® and linking it in Mastercam is we know how we want it, so we can build it again,” said Kaspar. “We build the structure as a wireframe and then extract the solid from that. We actually have hard edges to route from the machine path or the toolpath. It may cost a little more in time up front, but in the end, it saves us a bundle of time because we can program it much faster; we know which parts are ours.”

In order to get this part to the customer in two weeks, they performed model drafting using Mastercam’s Model Prep function, printing, and then running the actual toolpath itself. They broke the toolpaths into pieces and parts and put them back together again to see the whole. “We can build our stock models from raw materials and then we can take stuff off or add it as needed.”

Kaspar reflected on the time savings, “The quicker cuts get the job done faster. Generally, depending on a number of things, the right cut can save you a tremendous amount of time as well as tool life. We can plunge with the pocket and use the other three quarters length of the end mill instead of one quarter length which is essentially getting to the bottom. Time saving is the number one reason for us diving into the trickier cuts.”

For this operation they programmed the OptiRough toolpaths which use Dynamic Motion, but in a more precise way. The cut uses the entire flute length of the tool, but a small percentage of the tool’s diameter on the first cut, followed by several successive shorter cuts that bring the part into the net shape desired.

The result of being able to cut so deeply is the ability to push the machines. At times, Kaspar and crew can run the machines at 11,000 RPM spindle speed.

“Using Verify we can ensure the cut pre-posting, make the post, and read the post before sending it to the machine,” said Kaspar.

Kaspar relies on his local Mastercam Reseller, MLC CAD Systems, Inc. for training, post issues, and other questions. “Just a few weeks ago, our rep popped in as we were tackling a very difficult, complex part. It was great to have him visit, and he ended up spending four hours with us. Our posts are generally corrected within 24 to 48 hours, which is huge because there’s no stopping as far as yield,” said Kaspar.

Customer Quote

“Generally, depending on a number of things—materials being one of them and the amount of time needed with a particular tool—the right cut can save you a tremendous amount of time as well as tool life. We can plunge with the pocket and use the other three quarters length of the end mill instead of one quarter length which is essentially getting to the bottom. Time saving is the number one reason for us diving into the trickier cuts. Time is one of our most important assets and that is what these cuts will do.”

—Colter Kaspar, Owner/Operator, Kormachine, Waco, Texas
Reseller Quote

“Just a few weeks ago our rep popped in as we were tackling a very difficult complex part. It was great to have him visit, and he ended up spending four hours with us. Our posts are generally corrected within 24 to 48 hours, which is huge because there’s no stopping as far as yield.”

—Colter Kaspar, Owner/Operator, Kormachine, Waco, Texas

THE CHALLENGE


Deliver complex parts with unusual geometries and tight tolerances to aerospace customers within short timeframes.

THE SOLUTION


Mastercam, the most widely used CNC software for CAD/CAM operations.

BENEFITS


  • Solid model cut verification and machine simulation via Verify function ensure cutting accuracy.
  • OptiRough high speed toolpaths cut machining time, reduce tooling costs, and minimize machine wear and tear.
  • Model Prep function allows model drafting and editing without returning to the CAD file.
  • Seamless integration with SOLIDWORKS software allows models to be created and then modified for different toolpaths and machining processes.

Are you Shaping the Future of Manufacturing? Share your Mastercam Story Today!

Additional Case Studies

HoistDrum Machined
Mill
3D-Machine, Inc.

Learn More
Achates machine shop team using Mastercam
Mill
Achates Power

Learn More
Allstrap
Productivity+
Allstrap Success Story

Learn More
APS
Mill
APS Plastics Success Story

Learn More
Asnuntuck Machine Demo
Education
Asnuntuck Community College

Learn More
ATC students with Mastercam University certificates
Education
ATC Machining Technologies

Learn More
Bloomsburg High School Macine Shop
Education
Bloomsburg Area High School

Learn More
Cal Poly Mustang Rough Thumbnail
Education
California Polytechnic State University Uses DFM to Improve Engineering Skills

Learn More
Candor Bulldozer Thumbnail
Educational Suite
Candor Central High School

Learn More
Complex Parts Made Using Mastercam at Carolina Precision Components
Multiaxis
Carolina Precision Components, Inc.

Learn More
CVC Students and Professor
Education
Catawba Valley Community College

Learn More
CETech Innovations Owner Corey Easter
Job Shop
CETech Innovations

Learn More
chippewa Tech Student in mastercam
Education
Chippewa Valley Technical College

Learn More
3 pound double mount
Mill
Cornfield Crappie Gear

Learn More
Diversified Metal Crew
Mill
Diversified Metals Services, Inc.

Learn More
Quality Check
Mill
Don Schumacher Racing

Learn More
UAV Flight Components
Mill
Flying S, Inc.

Learn More
Mill
Grayco Machine Ltd.

Learn More
IUPUI Part engraved
Educational Suite
IUPUI School of Engineering and Technology Success Story

Learn More
Jacob Grey Cam
Mill
Jacob Grey Success Story

Learn More
Colter Kaspar Thumbnail
Mill
Kormachine

Learn More
Chest set
Education
Lincoln College of Technology Teaches Students CAD/CAM Programming

Learn More
Alex L and Kevin S Thumbnail
Mill
Loper Machine LLC

Learn More
MRS complex machined parts
Aerospace Defense
M.R.S. Machining

Learn More
Machine Nunn Thumbnail
Mill
Machine Nunn

Learn More
Madtown Skidplate
Mill
Madtown Guitars

Learn More
Multiaxis
Magnuson Products

Learn More
Mallory
Mill
Mallory Industries Success Story

Learn More
McAfee Machine Shop Thumbnail
Mill
McAfee Tool & Die

Learn More
Employees at Monsees Are Cross Trained
Design
Monsees Group

Learn More
New Bridge High School student using Mastercam for machining.
Education
New Bridge High School

Learn More
Spray Paint Gun in Mastercam
Mill
Northwood Industries

Learn More
NOVONestPlate
Lathe
NOVO Engineering

Learn More
OldenburgTechMachine Thumbnail
Mill
Oldenburg Metal Tech, Inc.

Learn More
Platt Instructors thumbnail
Education
Platt Technical High School

Learn More
Progressive Tool Employee Group Shot
Mill
Progressive Tool and Manufacturing, Inc.

Learn More
Education
Reed-Custer High School Guitars

Learn More
Mill
Royell Manufacturing, Inc. Uses Mastercam to Become a Tier 1 Manufacturer

Learn More
CAMIT Students in Shop
Education
Spartanburg Community College

Learn More
Specialized Bike Thumbnail
Consumer Goods
Specialized Bicycle Components

Learn More
Springfield Tech Community College
Education
Springfield Technical Community College

Learn More
Stark State Machine Shop thumbnail
Education
Stark State College

Learn More
STCC Students and Professors
Mill
STCC Summer Camp

Learn More
Car on Track Thumbnail
Mill
Stewart-Haas Racing and Mastercam Dynamic Motion

Learn More
Insulator Programmed in Mastercam
Productivity+
The H-J Family of Companies Success Story

Learn More
Trent Turner
Mill
Toner Machining Technologies

Learn More
Triple C Employees
Mill
Triple C Machine

Learn More
UCONN FSAE team
Educational Suite
UConn Formula SAE

Learn More
Tony and Alex Johnson
Aerospace Defense
United Machine & Metal Fabrication

Learn More
UTI Instructor in CNC Shop
Education
Universal Technical Institute – NASCAR Tech

Learn More
Van Buren Thumbnail
Educational Suite
Van Buren Technology Center

Learn More
Jess and Ben in Machine Shop
Mill
Van Dam Custom Boats

Learn More