Founded in 2015, Coventry-based Vigour Ltd has grown from a single five-axis machining centre into a specialist manufacturer of complex, tight-tolerance components. From the outset, the company has relied on Open Mind’s hyperMILL CAM software to support its demanding work. 

Founder and managing director Ashley Hatton identified an opportunity to differentiate Vigour by adopting five-axis machining and CADCAM from day one, at a time when much of the subcontract market remained focused on three-axis machining and programming at the machine control. The company now operates four full five-axis machines, including three automated DMG Mori eVo 50 models. 

Hatton had previously used hyperMILL during his career in Formula 1 and chose the software for its reliability, robustness and fast calculation times. “My business is built around hyperMILL; it’s been a pillar of success for the company,” he says. 

A key benefit is Vigour’s ability to program while machines are cutting. Hatton typically programs the initial roughing operations in around 15 minutes, allowing the machine to start cutting while he develops subsequent roughing and finishing strategies. This approach maximises spindle utilisation and minimises machine downtime. 

Confidence in hyperMILL’s simulation is central to the process. “There’s no single-blocking or prove-outs anymore,” says Hatton. “We run the simulation in the software. Once it’s gone through that with no collisions, it’s on the machine and running.” 

Vigour specialises in components that demand difficult machining, challenging materials and complex geometry. Its recent work includes MAR-M247 turbine wheels and complex 17-4PH H900 compressor wheels for micro gas turbine applications. These rotating assemblies require shaft-to-wheel runout of less than 5 µm across the complete assembly, demonstrating the precision achievable through Vigour’s five-axis and hyperMILL-based approach. 

More information www.openmind-tech.com

JWA CNC Precision is demonstrating how the right CAM technology can help manufacturers consistently and profitably manage complex components and demanding tolerances. The UK subcontractor produces around 2000 different components each year from a catalogue of 9000, with tolerances routinely reaching 5 µm. 

Working predominantly with non-ferrous materials, including aluminium, stainless steel, plastics and composites, Leicester-based JWA supplies one-off and medium-batch components for aerospace, defence and green energy applications.  

For more than 20 years, JWA has relied on Mastercam software as the foundation of its manufacturing infrastructure. Technical director Tim Shillabeer, who has extensive experience with multiple CAM platforms, says the software’s widespread use provides access to extensive knowledge and support, as well as training resources. 

However, JWA has gone beyond simply ‘using’ Mastercam. The company has developed standardised programming and set-up procedures that enable trained operators to move between jobs and machines with confidence. New employees can become proficient quickly, while annual refresher training helps maintain skills across the workforce. 

“As a long-time user of Mastercam, we’ve ironed out so many little nuances that work really well for us,” says Shillabeer. 

This standardisation has reduced machine downtime, shortened gaps between jobs, and eliminated hours lost through programming and set-up variations. It also enables JWA to respond rapidly to new manufacturing challenges using established libraries, defaults and processes. 

Describing the company as being “quite at the advanced end of the scale” in its use of Mastercam, managing director Pete Wood says the approach has helped JWA maintain demanding quality standards while scaling its operations. It has also supported the company’s achievement of AS9100 certification and created a flexible, skilled workforce capable of handling its diverse production requirements. 

More information www.mastercam.com