In digital manufacturing, CAM systems are the bridge between virtual planning and real production. However, there is one key component that is often underestimated but is essential for the seamless implementation of this planning on machine tools: the postprocessor. It translates CAM-generated data into CNC-compatible code that provides the machine control with the correct structures and sequences. But modern postprocessors, such as those from ECS Engineering Consulting & Solutions, act as intermediaries between CAM software and machine tools. They can do much more than just translate data—they are the key to efficiency, flexibility, and competitive advantages in manufacturing.
Different machine controls have specific requirements for the structure and syntax of data. The idea that the postprocessor merely translates the tool paths of a CAM system into motion sequences is no longer sufficient today. Modern controls offer extensive options such as jump commands, loops, and if-then conditions to optimize the machining process. The targeted use of postprocessors can improve machine control sequences, resulting in shorter machining times, less machine downtime, and higher precision!
“The postprocessor isn't everything, but without it, everything is nothing.”
NX software and machine tools are standardized products, but the postprocessor makes all the difference. OOTB (out of the box) solutions offer some customization options, but your own manufacturing process is often more unique than you might think.
Customized postprocessors can be adapted to individual requirements and allow optimal use of the CAM software employed. This enables a consistent, efficient, and future-proof manufacturing concept.
Working with customers to develop customized solutions
While competitors often rely on standard solutions, ECS develops postprocessors as a service in close consultation with its customers. This paves the way for fully exploiting manufacturing potential while avoiding long-term maintenance contracts. Users also benefit from maximum control over their systems and extremely short generation times, ensuring a fast return on investment.
The following practical example provides an impressive illustration of the capabilities of customized postprocessors: PTFE Nünchritz is a renowned contract manufacturer of high-quality plastic parts. As an expert in the processing of polytetrafluoroethylene (PTFE) and other high-performance plastics, it offers a comprehensive range of services. This includes the development and manufacture of PTFE compounds, the production of PTFE semi-finished products, and the machining of customer-specific sealing and construction elements.
(www.ptfe-nuenchritz.de). PTFE Nünchritz positions itself as a flexible and reliable partner for customized solutions in the field of seals and construction elements made of high-performance plastics.
The initial situation
PTFE had developed a structure for the NC file: When manufacturing repeat parts from a plate, the machine operator only has to enter the correct parameters at the beginning of the NC file—the machining then runs automatically. This resulted in the development of an NC file layout that precisely meets the requirements and is easy for machine operators to navigate.
On the other hand, there is the CAM system for programming tool paths, which is used to program a component only once. The NC file therefore had to be edited manually in order to insert the repeat part loops into the NC program.
The task
The existing postprocessor for single-part production was to be expanded so that, at the touch of a button, it could generate the complete NC program with all tool paths, the proven input structure at the beginning of the NC file, and all loops and repetitions during program execution.
Specifically, the following requirements had to be met in order to produce several identical components from a plastic sheet:
- The component should only be programmed once with all machining operations in the CAM system.
- It should be possible to mill the entire plate (blank) once if necessary.
- It must be possible to manufacture only one component initially so that it can undergo quality control—and only after it has passed the test can the remaining components be manufactured (the first component will of course no longer be needed!).
- In order to utilize the slab as completely as possible, it may be necessary to cut some components lengthwise and others crosswise (rotated) from the slab.
- Minor geometric corrections to the position of the raw material should still be possible.
- The structure should be mapped to both Heidenhain and Sinumerik controls.
- In CAM programming, it must be possible to optimize the machining sequence so that machining time is minimized in terms of tool changes and empty runs.
The ECS solution
This is where ECS Engineering Consulting & Solutions from Neumarkt in the Upper Palatinate comes into play. An input mask was created for the CAM programmer, in which he only has to enter the key data for the repeat parts. These are the number of parts in the X and Y directions and the distances between the machining positions in the X and Y directions.
From this, the post-processor solution customized by ECS generates a complete NC file with the following structure:
- Input option for control parameters for the machine operator
- All tool paths in subroutines (label)
- Zero point calls in subroutines (label)
- the flow structure with loops and jump commands
Both Heidenhain and Sinumerik controls were seamlessly integrated—without changing the input field for the operator. A key advantage of this solution is the automatic optimization of the
Machining sequence. Empty strokes are minimized, tool changes are made more efficient, and the overall machining time is reduced. At the same time, the programming effort for the CAM user remains minimal: The tool paths only need to be defined once and the key data for the sample field entered – regardless of the control system used later. NX-CAM offers the option of genuine NC code simulation: This means that the CAM programmer has integrated a model of their real machine's geometry and control system into the CAM software. The NC commands can be read and processed in exactly the same way as in reality. With this ‚digital twin‘, the CAM programmer can check in advance whether the NC file has been generated correctly and whether the manufacturing process corresponds exactly to the planning. Thanks to this customer-specific solution, PTFE benefits from complete flexibility in production while minimizing programming effort and maximizing repeat accuracy.
Real competitive advantages through technological openness
The post-processors are technologically open, meaning that preconfigured solutions are not used if they do not offer any added value. This allows maximum flexibility for different manufacturing requirements; necessary adjustments usually involve comparatively little effort.
ECS's customized postprocessors for individual manufacturing offer:
- Excellent generation runtimes: Minimization of machine downtime and faster production.
- Maximum adaptability: Individual NC code output exactly according to customer requirements.
- Uniform concept for the entire machine park: Simplification of NX CAM programming for all machines.
- Future-proof: ECS post-processors remain stable even after NX updates.
- NC code machine simulation included: High fidelity thanks to direct integration in NX-CAM.
- Special interface between CAM system and machine: ECS postprocessors stand out from conventional solutions thanks to their intelligent structure.
- Open source code: ECS post-processors are not encrypted, meaning they remain independent of service providers and maintenance contracts.
ECS customers also benefit from high speed NC file generation (postprocessor run): ECS's ‚turbo mode‘ significantly reduces waiting times for CAM programmers.
Conclusion
Postprocessors are indispensable for the efficient implementation of digital manufacturing processes. Companies such as PTFE demonstrate that a custom-developed postprocessor not only improves production, but also saves long-term costs and ensures competitiveness.
The customized ECS solutions optimize technological processes and also deliver economic benefits. With ECS expertise, customers can take their manufacturing processes to the next level—efficient, flexible, and future-proof.