ModuleWorks product Brochure

ModuleWorks Get There Faster.

The Future is coming -

Get There Faster

The fast pace of technological development and the increasing complexity of parts are placing CAD/CAM software developers under increasing pressure. To remain competitive, the latest technologies must be available for end-users in the shortest possible time. However, in-house solutions often fall short due to lack of knowhow or limited resources.

We increase your competitiveness and accelerate your time to market by quickly and reliably integrating a broad spectrum of the leading and industry-proven CAD/CAM technology into your software solution.

As an independent company with a global reach, we continuously invest in developing innovative technology and work in partnership with our customers to enable you to master every challenge.

Why ModuleWorks?

ModuleWorks is your go-to partner for CAD/CAM software. From standard products to exclusive development projects, we work closely together with you as a partner to bring your own vision of Industry 4.0 to life. With our comprehensive product portfolio and cutting-edge software components, you can optimize your CAD/CAM solutions and succesfully connect to CNC/MTB sytems to rapidly increase your competitiveness.

Within a week your personal ModuleWorks consultant will prepare a prototype integration that simplifies and accelerates your decision making based on a well-founded analysis.

We have always invested in the development of innovative, future-oriented technology and the continued development of our solutions.

As a ModuleWorks customer, you benefit from the latest features delivered in 3 guaranteed software releases per year to ensure that your software product is always at the forefront of the latest technological advances.

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About

ModuleWorks ModuleWorks develops state-of-the-art toolpath generation and simulation component technology for Computer Aided Manufacturing (CAM) applications.

ModuleWorks was founded by Yavuz Murtezaoglu in 2003 as a specialist software company for 5-axis machining, but the origins of the company can be traced back to the 1990s.

During that time, Yavuz was a partner with a successful German Mastercam reseller, Camaix, developing 5-axis machining technology as a plug-in for the Mastercam product.

With the success of the initial 5-axis plug-in it became apparent there was a strong demand for the technology in the wider CAD/CAM industry, and so ModuleWorks was born as an

independent CAD/CAM component supplier offering industry-proven 5-axis machining software.

ModuleWorks started with a small number of industry partners, but the strength of the technology and increasing worldwide demand for 5-axis machining meant rapid growth and we soon had many additional partners.

Today, in 2018, we have more than 150 industry partners and over 500,000 installed seats of software around the world.

A Great Place to Work!

To ensure our leading position at the cuttingedge of technological development, we invest heavily in R&D and now we have development centers in Germany, Romania, Ukraine, Russia and the UK. Our team is more than 170 strong with the vast majority focused purely on R&D. With over 600 man years of ongoing software development, we deliver our latest technological advances in three new releases each year.

We have no end-user products, allowing us to dedicate our resources to meeting the needs of our partners.

The product range has steadily grown with the addition of components for simulation and 3-axis machining as well as sophisticated industry focused solutions for dental, woodworking, blade and port machining. For CNC manufacturers and

machine tool builders we offer the full range of our proven toolpath generation and simulation techology directly on the CNC controller, from intuitive job setup software to sophisticated realtime collision avoidance technology for safer and more cost-effective machining. In addition to component development, we support our partners with custom development projects to integrate and extend our technology to meet your individual requirements.

Recent surveys organized by Great Place To WorkTM recognized ModuleWorks as one of the “Best Employers in Germany” across all industrial and business sectors.

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For an easy to use way to get started

5-Axis Basic

The 5-axis components offer high programming flexibility for roughing and finishing toolpath cycles for a vast diversity of parts, from generic toolpath patterns on surfaces and meshes to part-specific tailored applications for maximum automation and safety. Everything is delivered in a fully comprehensive object-oriented API that enables fast and easy integration into a host application. A basic, standard and professional package optimize the value of your portfolio. Dedicated part-specific training, numerous examples and hands-on applications help you get the best return on your investment.

Basic Package This package is for users who need basic functionality or who are new to 5-axis machining. The toolpath cycles are easy-to-use applications with minimum user input, automatic tool axis control and collision avoidance. The package is suitable for trimming and drill jobs, 5-axis finishing for M&D parts as well as flank milling of 5-axis pockets.

The package includes: • SWARF, contouring, deburring • Drilling • Autotilt 3 to 5

SWARF SWARF (Side Wall Axial Relief Feed) machining, or also called „flank milling“, is a 5-axis simultaneous milling process. It is used for machining fluid parts for turboengines or aeronautical parts such as integral elements. The target surface is produced with only one cut, using the whole flute length of the tool.

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Deburring This deburring module creates toolpaths on the outer edges of a part‘s geometry. The system includes automatic feature detection, automatic linking, automatic lead-in and automatic collision avoidance. After selecting the part geometry, the toolpath is created fully automatically.

Autotilt 3 to 5 This option converts a 3-axis input toolpath to a fullly automatic collision-checked 5-axis toolpath.

The 3-axis toolpath is used with a much shorter tool. Automatic tilting compensates the holder with the geometry and tilts it away.

For a full range of power and flexibility

5-Axis Standard

This package enables you to use all generic 4- and 5-axis function.

Standard Package Both roughing and finishing cycles are available.

The user has manual control over the pattern, tool axis, linking and collision avoidance. Any part can be machined.

The package includes: • Surface/geodesic/wireframe pattern generator • Multi-axis roughing • Rotary roughing/finishing and turn mill • Toolpath conversion

Generic Pattern Generator This pattern generator works on surfaces and meshes. Surface-based machining creates toolpaths with a low tolerance suitable for 5-axis production machining and optics machining.

Mesh-based machining is optimal for creating overall finishing toolpaths on complex geometries due to its robustness and ability to calculate constant stepovers on complex shapes.

Multi-axis Roughing This cycle creates a roughing toolpath for 5-axis pockets, i.e. pockets with a curved floor. Both the offset pattern and the adaptive machining pattern are available.

Rotary and Turn Milling These components create roughing and finishing toolpaths for turnmill parts. With the turn-mill cycle you generate a milling toolpath for creating a turning profile. Rotary machining lets you create roughing and finishing toolpaths in the pockets, slots and grooves.

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For optimised results on specialised parts

5-Axis Professional

This package offers the complete range of 5-axis toolpath cycles.

Professional Package In addition to the standard pattern, it offers special applications for port machining and impeller/ blisk machining. These applications are dedicated modules for producing these special types of parts with automatic roughing and finishing, linking, tool axis control and collision avoidance.

Other advanced applications are also available: • Port • Multiblade • 3+2 auto rough • Mesh tools

Port Ports are usually found where fluids need to be transported into or out of machines such as car engines and turbo machinery. Port machining is used to create roughing and finishing toolpaths for port-type geometries. Port machining makes it easy to reach the full area with a single toolpath, machining from the top and the bottom.

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Multiblade Multiblade parts, such as impellers and bladed disks (so called „blisks“), are very complex and very thin which makes them difficult to produce. The multiblade package automates the roughing, rest roughing and finishing for the blade and root.

3+2 Auto Rough The biggest challenges in roughing a part, especially parts with many undercuts, are finding the right directions for positional machining to remove all the material and avoiding potential collisions with the current rest material. 3+2 auto rough combines all of this in a single automatic cycle that makes it very easy to use.

To support the full CAM process

Utilities

ModuleWorks offers several utilites to cover a wide range of needs beyond basic toolpath calculation and simulation. With ModuleWorks Utilities you can fix 3D meshes, simulate stock and edit NC code to fill any gaps in automated CAD/CAM processes.

Mesh Tools The Mesh Toolkit is a collection of functions for creating and modifying triangle meshes.

Originating from internal use in our own algorithmic development, we saw the benefits they could bring to our clients and decided to condense them into a product.

Several mesh-healing, slicing and generation algorithms are included in this package. The clean and easy to use programming interface allows you to get the maximum benefit out of the Mesh Toolkit for your own operation.

NC Editor NC Editor is a powerful editing and simulation tool for NC files for milling and turning applications.

It lets you view and make simple changes to the G-code directly on the shop floor. It can be easily configured for almost any CNC control and offers a color coded textual and graphical view of the NC code.

Stock Manager The Stock Manager tracks and stores the current status of the rest material. It enables users to obtain the rest material stock for consecutive toolpath calculations or an intermediate stock model for the simulation. The Stock Manager can handle multiple workpieces and complex multistock simulations.

PP-Framework The Post-Processor-Framework (PPF) lets you script the NC-output for any custom machine tool. PPF uses the MultiXPost component as a front-end. Alternatively, you can integrate the software via the API (C#/C++) into your own toolpath environment, independent of the ModuleWorks toolpath calculation.

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For machining complex Mold and Die parts

3-Axis

The ModuleWorks 3-axis machining component uses STL mesh geometry to generate accurate gouge-free toolpaths on 3D models.

The library offers a full range of flexible roughing and finishing machining strategies, including intelligent adaptive roughing, rest roughing, flatlands, pencil machining and rest finishing.

ModuleWorks 3-axis adaptive roughing maintains a constant tool load and smooth toolpath to dramatically increase material removal rates, lower cycle times and extend tool life.

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All machining strategies are optimized for high-speed machining applications offering intelligent ordering, corner rounding, smooth leads and efficient linking transitions between passes.

Each finishing strategy respects the stock definition and includes automatic rest material, steep, shallow and flatland detection to reduce cycle times and provide a high-quality surface finish.

For machining prismatic parts

2-Axis

ModuleWorks also provides a range of toolpaths to meet your needs for 2D + 2½D applications on prismatic type parts.

Conventional lace and concentric pocketing strategies are complimented by state-of-the-art adaptive roughing which maintains a constant tool load and smooth toolpath for faster cutting rates, lower cycle times and extended tool life.

The engraving toolpath is ideal for sign making and other artwork applications giving an artistic finish to sharp and fully detailed shapes and lettering.

The engraving cycle supports roughing and finishing and allows machining with the tapered cutters commonly used for these applications.

Contour finishing provides singlepass or multi-pass strategies with a full range of lead-in/lead-out options to provide optimal cutting conditions and support for G41/G42.

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To optimise material removal rates

Adaptive Roughing

ModuleWorks Adaptive Roughing is a cornerstone of its state-of-the-art machining technology providing the very latest techniques for high-speed machining.

Adaptive Roughing maintains a consistent tool engagement and delivers smooth toolpath motion to dramatically increase material removal rates, reduce cycle time and extend tool life.

ModuleWorks Adaptive Roughing can be applied as a machining strategy on wireframe geometry (2D and 2½D), and all forms of 3D geometry (solids, surfaces and STL mesh). All the standard 3-axis roughing features are fully supported.

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A full 5-axis adaptive roughing strategy allows the technology to be used in almost any machining scenario.

Adaptive Roughing includes full support for open pockets, arbitrary stock models, intermediate slices and rest roughing. Pre-drill holes and a range of ramp options are included.

For machining rotational parts

Turning

The ModuleWorks Turning Module provides powerful and easy to use toolpaths for lathes and turn-mill machines.

This component offers a full range of traditional turning cycles together with advanced features which can be combined with rotary, 3-axis and 5-axis modules to program any complex operation.

Collision-free turning toolpaths enable efficient processing of both outer and inner surfaces.

Adaptive roughing maintains consistent cutting conditions with high machining feed rates which significantly reduce machining time and extend the life cycle of the tool.

The Turning calculation engine supports parametric and custom lathe tools with gouge checking for cutting and non-cutting parts.

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To bring CAM technology closer to the machine

CNC and Machine Tools

Recent advances in CNC control hardware have made both simulation and toolpath technology a reality on CNC controls. ModuleWorks has been working with control manufacturers and machine tool builders to implement the ModuleWorks simulation and toolpath technology on CNC controls.

Simulation refers to both material removal and additive simulation as well as full clash detection for the machine kinematics. Advanced features such as toolpath analysis provide safer process control as well as new levels of optimization.

Toolpath technology on CNC controls includes advanced cycles such as adaptive roughing technology for optimized toolpaths that reduce machining time and tool wear.

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Modern toolpath cycles environments with full 3D support and a state-of-the-art user experience (UX) become a possibility, making full use of current CNC control hardware.

Advanced simulation features, such as full scene collision checking, tool engagement calculation or chip volume calculation can be used during job preparation directly on the CNC control for safer process control.

To avoid expensive mistakes

Real-Time Collision Avoidance

Real-time simulation has become a possibility on modern CNC control hardware, allowing full-scene collision avoidance directly on the CNC control.

By working directly with manufacturers of CNC controls, our development teams have delivered simulation technology to the CNC control, providing a real-time collision-free environment that helps to ensure a safe and right-first-time manufacturing process.

Implementations are designed according to CNC / PLC hardware capabilities.

The ModuleWorks Collision Avoidance system can be integrated using different communication protocols, allowing a high level of flexibility. No G-code parsing is required. The simulation uses the actual axis positions as calculated by the CNC interpolator.

Collision detection works on real 3D objects and includes proximity alert functions with multiple safety distances.

This functionality can be used to define maximum feed rates based on the proximity of critical objects in JOG mode.

In AUTO mode, process intervention will only occur if a look-ahead collision is detected, in which case a STOP signal is sent to the CNC control.

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To provide an accurate virtual model

Cutting Simulation

ModuleWorks Cutting Simulation adds value to your application with high-performance verification to provide highly accurate verification of stock removal for milling, turning and combined mill/ turn applications.

The Cutting Simulation component is fast and accurate even with the largest and most complex multi-axis toolpaths. Adaptive refinement technology shows precise definition of the machined component, even on the smallest of features.

A full range of error detection tools is provided and verification can be programmed to stop when collisions are detected, allowing immediate identification and correction of any programming errors.

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Analysis tools can detect and measure gouges and areas of excess material on the final cut model which can be saved as an STL mesh for use in subsequent manufacturing operations.

Animation allows users to preview what will happen on the machine.

A video-style user interface allows users to pause, play, step, rewind and fast-forward through the toolpath.

To understand complex movements

Machine Simulation

ModuleWorks state-of-the-art simulation components empower your application with high-performance machine simulation and toolpath verification tools.

The Machine Simulation component provides support for milling, turning, CMM, robotic, woodworking and dental applications and can be tailored for custom applications via flexible kinematic definition, powerful APIs and other customization tools.

ModuleWorks Machine Simulation can be used from the simple to the most complex of machining operations including 5-axis and combined mill/ turn machining.

A library of more than 100 different machine kinematics is provided as a starting point, but virtually any kinematic combination is supported.

Machine Simulation gives you a complete virtual environment for detecting potentially dangerous problems such as proximity alerts, collisions and axis overrun errors, helping to ensure a safe and optimal machining environment.

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To enable the latest manufacturing developments

Additive and Hybrid

The ModuleWorks Hybrid module includes 3D printing solutions for all major additive processes plus a hybrid machining module with all the ModuleWorks 3-axis to 5-axis milling, post processesing and finishing strategies.

Our additive path planning strategies are developed in a close cooperation with industry partners to cover all features that are essential to produce an efficient process with high quality results.

ModuleWorks additive solutions are optimized for e.g. SLS, FDM and DLP path generation and process optimization. Included are special features to decrease data amount, get better surface quality and reduce build time. ModuleWorks offers a comprehensive API that enables a fast and easy integration into a host system.

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The ModuleWorks mesh healing and mesh decimation functionalities help to prepare the workpiece before the slicing process to ensure exact part contours and infill patterns.

ModuleWorks provides machine and material simulation to validate process parameters such as sorting, startpoints, overlap, infill density and support placement.

The simulation results can be used for further machining like removing support structures or create finishing operations to increase surface quality.

Dedicated support for specialised requirements

Applications

The flexibility of the ModuleWorks components allows them to be used in a wide variety of areas and applications like Dental, Wood and Optics.

Each application is different in material, machine type and machining pattern or process sequencing.

ModuleWorks offers an advanced programming environment that offers both conventional milling and turning strategies but also dedicated features and parameters that are required by each process.

The Dental Framework is tailored specifically for the dental industry and provides high-performance 3-axis to 5-axis milling and grinding strategies combined with a post processor for a variety of dental milling machines. It can be used for fast and efficient manufacture of dental components such as copings, crowns, inlays, bridges and many others.

The wood component is tailored to the needs of the woodworking industry. It includes 3-axis to 5-axis toolpath generation strategies and a comprehensive simulation package. In addition to the standard machining operations, the framework offers support for drill blocks, aggregates, form tools, saw cutting and optimization for large panel parts.

The OpticsCAM software is a tailored kernel for ultra-precision machining. It provides 2-axis to 6-axis machining patterns combined with a flexible, fast and highly accurate post processor framework for different optics machines and is able to output big data NC-files.

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ModuleWorks Partners

ModuleWorks GmbH Henricistrasse 50 Aachen, Germany Tel: +49 241 99 000 40 info@moduleworks.com www.moduleworks.com