Doug Rhoda

Why the Nikon SLM Solutions NXG 600E is the UNDISPUTED Gold Standard in Metal Additive Manufacturing: - 12x 1000W Lasers: Blazing speed for high-volume production – melt metal powder faster. - Massive Build Volume (600x600x1500mm): Tackle aerospace & defense giants without compromise.  - Precision Perfected: End-to-end workflow ensures flawless parts, revolutionizing supply chains.  The future of industrial 3D printing. #NXG600E #AdditiveManufacturing #3DPrinting #AerospaceInnovation

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We over-bought on our nine-axis lathe. Didn't have immediate work for it, and my lead machinist had never programmed one. But he recommended it with the Haberle five-axis mill, and I trust his judgment. A year later, both machines run 23/7 just kicking out parts. Yes, there's sticker shock. Then you find out chucks are another $10K on top. Lots of peripheral costs you don't see coming as a new owner. But...when you hold tolerances others can't and match cycle times they can't, you're not competing on price anymore. I learned this from quality: you can't inspect it in, you have to build it in. Same with capability. You can't retrofit precision into old equipment. Sometimes you invest in advanced machinery before the work justifies it, because the work won't come until you have the capability.

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What’s going on with CAM post processors? Why does every CNC machinist or NC programming manager I talk to ask me: “Can your AI also do the post processing?” “Because the post we have today is terrible, and we can't find anyone to develop a proper post processor script.” Why is post processing treated like black magic that only a few experts can do? And why is this field still so unsolved? Yes, I know there are online hubs where you can download official post processors — but from what I’ve seen, they’re only for simple machines without advanced capabilities. I see machine companies providing these services outside the machine deal itself. I see CAM companies sending technical engineers for weeks to the client’s production floor just to get the machine running. And I see resellers offering these same services. Why is it such a no-man’s land when it comes to connecting CNC machines with CAM software? I understand there’s a need for specific customization for each machine configuration, but it’s not black magic. Honestly, I don’t get it. You buy any car, you drive it. You buy any computer, you turn it on and good to go. You buy a 3D printer, you operate it in few hours. You buy a CNC machine, pay thousands of dollars for a complex post-processor, and then wait six months to debug all the issues. Does that sound reasonable for 2025? I even meet customers who base their decision on which CAM solution to use solely on whether they know someone who can handle the post processors for that specific machine! Do you think this will change soon? who will take full ownership on this pain? software provides? machine providers? resellers? #CNC #CAM #postprocessing #CNCmachines #manufacturing #PhysicalAI #Machinists #NCprogramming

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Chip formation Tuesday! One of the most important realizations I have had in my studies of the science of metal cutting is that virtually every machined surface was produced under so-called ‘ploughing’ conditions. While we typically think of metal cutting as cleanly removing a macroscopic chip, the intrinsic geometry of most machining operations results in the uncut chip thickness (the geometry of the material being removed, i.e., the chip load) to become zero at some point on the machined surface. Helpful insights into how metal cutting occurs can be found from the field of Tribology (the science of friction, wear, and lubrication) in the different modes of sliding contact. With increasing pressure between two sliding bodies (e.g., a tool and workpiece), there will a transition from sliding to ploughing, i.e., some plastic deformation ahead of and underneath the sliding contact. With sufficient normal pressure, we begin to remove material; Tribologists call this phenomenon abrasive wear, and metal cutting can be considered a special (controlled) case of this kind of sliding contact. Because the transition from sliding to ploughing to cutting is gradual, each prior mode will be present in a subsequent mode. In other words, there is no cutting without at least some amount of ploughing and sliding, unless cutting occurs via perfectly brittle fracture. While there is still some debate around the presence of ploughing beyond some ‘minimum uncut chip thickness,’ I feel that this issue was definitively solved by a landmark paper from H.J. Lambert in 1961. Lambert showed that the entire uncut chip geometry includes some minimum uncut chip thickness material that can only be cut during a subsequent tool pass/rotation. In other words, metal cutting always includes some ploughing and some sliding, as we transition from the severe plastic deformation in the shear zone(s) to sticking and sliding friction regimes on the tool rake and flank faces. The severity of ploughing, which again is an inevitable part of all cutting processes, is directly linked to the finite sharpness of the cutting tool. This insight can be traced back to early work by P. Albrecht in 1960. The larger the cutting edge radius or hone, the greater the ‘edge forces’ due to ploughing. Today’s video captures what I believe may be the first ultra-high-speed video sequence (100,000 fps, 159 ns exposure) captured at sufficiently high magnification (50x, 400 nm/pixel) to resolve an extremely small 4-micron uncut chip thickness in cutting of Ti-6Al4V alloy at 60 m/min. Even though the tool is relatively ‘sharp,’ there clearly is some ploughing at such low uncut chip thickness. This condition is representative of surface generation in finish milling and turning, even when the maximum and average uncut chip thickness values reach much larger values on the uncut shoulder, away from the final surface. Let me know how you think about and control ploughing and size effects in finish machining!

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Feel the finish. It tells the story of the process. Every surface on a machined part is more than just metal— It’s evidence of the method, the tool, the parameters, the material, and the precision behind it. A rough patch might whisper: high feed rate, dull tool, or skipped coolant. A mirror-smooth face? It reflects intention, refinement, and process mastery. In manufacturing and mechanical engineering, surface finish isn’t just about aesthetics. It impacts: Wear and tear Friction behavior Coating performance Fluid dynamics Functional fit Product lifespan Each mark left behind by turning, milling, grinding, EDM, or polishing— Is like a fingerprint. And when you're chasing tight tolerances and high-performance outputs, surface finish becomes non-negotiable. Engineers know: smooth isn’t always better. What matters is the right finish for the right function. And if you’ve been on a shop floor long enough, you know— You can feel a good finish. You can hear it coming off the tool. You can see if the process was dialed in—or if it was just a pass for production’s sake. So next time you inspect a component—go beyond the specs. Feel the finish. Because it reveals what the numbers can’t. #SurfaceFinish #ManufacturingMatters #MachiningPrecision #EngineeringExcellence #DesignForManufacturing #CNCExperts #MechanicalEngineering #ProductionQuality #ProcessControl #MadeWithPride

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The Mills Machine Works Difference When you're sourcing a machining partner, trust is everything. You need a shop that delivers precision, reliability, and problem-solving expertise—without excuses. 🔹 Experience: With years of hands-on machining and engineering expertise, we know how to take your designs from concept to reality. 🔹 Quality Assurance: Every part we produce meets strict tolerances and undergoes rigorous inspections to ensure reliability in the field. 🔹 Partnership Mentality: We don’t just make parts—we solve problems, optimize designs for manufacturability, and help you hit deadlines without stress. At Mills Machine Works, we take pride in being more than a vendor. We’re an extension of your team. If you’re tired of suppliers missing deadlines or sending subpar parts, let’s talk. #Manufacturing #PrecisionMachining #Engineering #CNC #SupplyChain #MillsMachineWorks

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What happens when you give a team of tooling application engineers a Makino PS65 and a blank slate? You get breakthrough ideas, faster problem-solving, and real-world results that matter to our customers. From pushing tool geometry boundaries to refining chip control and surface finish - Fullerton's R&D Lab isn't just testing theories. We're building solutions. Want to see how innovation actually happens? Watch the video or read our blog at:. https://hubs.li/Q03tRm2L0

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We wasted hours fixing errors between design and machining—until we stopped treating CAD and CAM as separate. Here's what changed everything 👇 For years, I struggled with constant back-and-forth between the design team and the shop floor. It was frustrating. Errors kept creeping in. Toolpaths were constantly adjusted, simulations didn’t match real-world results, and everything took twice as long. Then we made a game-changing decision: we integrated CAD and CAM. Fusion 360 bridged the gap between design and manufacturing. No more disconnected systems. No more miscommunication. Here’s what that integration did for us: Real-time updates—Design and machining are connected, eliminating the need for constant back-and-forth. Streamlined workflow—Toolpath creation becomes an extension of the design process. Fewer errors, faster prototyping—Design changes directly flow into the CAM system without the usual confusion. The result? A faster, smoother, and more predictable workflow, all thanks to Fusion 360. The time we once spent fixing errors is now used for innovating and scaling. 📩 DM me if you’re still stuck in the past with separate CAD and CAM systems. I’ve been there, and I can help you make the switch. #Fusion360 #CADtoCAM #Manufacturing #DesignToManufacturing #Innovation #CNC #SmartManufacturing #WorkflowOptimization

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