Like all European mould makers, BE, a toolmaker in New Milton, Hampshire, faces international competition. However, partner Geoff Elvy, is convinced that the problem is not so much global competition but more the inability of some toolmakers to adapt to new technology. BEC realised that toolmaking today has become a team effort, where designers, toolmakers and plastics specialists have to co-operate to produce optimum results.

Consequently BEC has invested not only in CAD/CAM to cover the design aspects of toolmaking, but also in injection moulding equipment to actually produce the parts.

Many mould makers only set up CAD/CAM systems when their customers force them to do so.

In BEC's case it was the other way around.

About three years ago the company set up its own CAD department and then started to convince its customers of the benefits of supplying CAD files instead of drawings.

At that time it was common practice for customers to supply 2D drawings for 3D models.

Although some of BEC's customers still work like that today, the majority of new designs arrive as CAD files.

This is not only faster but also safer, since the moulds are machined from the original model data.

It also helps the toolmaker to visualise what the finished part will look like.

Geoff points out that the company is not tied to any particular CAD system, as customers supply data in a number of different formats.

These designs are usually imported as IGES files with trimmed surfaces.

Solid models are not used commonly yet, but BEC feels that this technology is finally getting to the stage where it can be used effectively.

Modern telecommunications has hastened the whole process.

Files are usually sent via e-mail and imported into the CAD system to check for surface gaps and manufacturability.

After that, cam software is used to calculate the NC code for the cutter paths.

Typically, the NC milling equipment starts to cut the mould only two hours after receipt of the CAD files, so by the end of the day the mould is finished.

It is then either shipped to the customer or used directly at BEC's in-house moulding facility.

This injection moulding machinery ranges from 12 to 250 tons for parts up to 500 mm x 500 mm.

BEC moulds standard as well as specialised grades with various fillings from glass to stainless steel.

The in-house moulding facilities are used for everything from one-off prototype samples to full production batch runs.

However, BEC is not simply importing finished designs but also offers to help customers with the initial and detail design of their products.

When a customer arrives with an idea of what he wants, BEC will first draw a hand sketch in one or two days.

One more day and the customer can already see for approval a photo-realistic image of his product, designed with Autodesk's 3D Studio.

Customers greatly appreciate this service.

They are usually in a hurry to get their design to market so there is no time to machine prototypes.

If required, BEC can prepare a 3D computer simulation to produce an accurate impression of what the part will look like, which can even be exchanged via e-mail.

In this way the finished product can be delivered to the customer just three to four weeks after the initial design.

BEC has used different CAD/CAM software since 1984, continuously upgrading to stay at the forefront of technology.

In 1997, BEC was again looking for an alternative to the system they were then using.

Among the companies that presented CAD/CAM solutions was an Autodesk dealer that focused on mechanical applications.

BEC was a little sceptical whether this system could handle the sophisticated 3D applications they were used to, but a demonstration convinced them.

The dealer explained, 'Many people still see Autodesk as a 2D drawing system, but autodesk mechanical desktop has all the 3D functionality for demanding surface and solid models.

We offer Autodesk Mechanical Desktop in combination with hyperMILL from OPEN MIND, an integrated CAM application that converts the CAD designs directly into NC code for machining.' The BEC people were pleasantly surprised by the performance of this PC-based CAD/CAM package.

Geoff is convinced that he took the right decision, 'We scored a winner,' he said.

'We spent less money and can do a lot more with it.' One major issue was the versatility of the CAD system.

BEC receives files in a large variety of CAD formats, and Autodesk Mechanical Desktop offers all the necessary interfaces to handle the different files.

'We have never come across a file that we couldn't import,' commented Geoff.

BEC is not only pleased with the CAD functions of its system, but also with the CAM functionality it offers.

A number of automatic machining functions greatly reduce the time for NC programming.

The system can be set to analyse a CAD model and choose the best machining strategies for different surfaces.

There is also a function for automatic rest milling, whereby a mould is first machined with a large cutter, then the remaining material is automatically detected and re-machined with a smaller tool.

This reduces the machining time as the larger cutter quickly roughs out the material while small cutters are only used where necessary.

From the toolroom, the NC programs are transferred to a Bridgeport mill on the shopfloor via DNC link.

Reliable cutter path generation is another major issue for BEC, as for any toolmaker.

Geoff explained, 'Time-to-market is the major concern today, so you've got to get it right first time.

That takes confidence and our CAD/CAM solution gives us this confidence.' He knows from experience that not all CAD designs arrive in perfect shape.

Sometimes there are gaps between the surfaces which are hardly noticeable on the screen.

On the old cam system the cutter would frequently 'drop' into these gaps.

To prevent the cutter from hitting the fixture, artificial safety planes had to be designed into the customer models.

Today this is no longer necessary, as an advanced mathematical model is used to calculate a polyhedral mesh over the CAD geometry and cutter paths are superimposed.

The mesh automatically covers the gaps in the CAD model, so that the cutter does not fall into a gap when machining the model.

The other great advantage of this approach is reliable gouge and undercut checking over the entire model.

The user can therefore rest assured that the NC code will indeed cut the desired geometry and will not damage the mould, cutter or fixtures.

BEC is now even running the NC mills during the night, something they never dared to do with the old CAM system.

Geoff is convinced that he took the right decision when investing in a new CAD/CAM system.

He concluded, 'The package we are using now is very good indeed.

Presently I wouldn't consider buying anything else.' He pointed out that it is not just the growth, currently around 10 per cent annually, which leads him to say this but also the increased profitability thanks to the use of state-of-the-art CAD/CAM technology.

A third NC programming station was installed in 1999 and this year an additional station was added for mould flow analysis.

This reflects BEC's philosophy of gradual evolution, rather than rapid expansion.

Serving the existing customer base has priority over winning new orders.

Where other companies boast about the number of new customers they win, BEC is proud not to have lost a single customer in more than three years.

With this approach the company has built long term alliances with key players from different industries.

One example of this is the relationship with Racal, for whom BEC first produced a point-of-sale credit card terminal back in 1981.

Since then they have been involved in the production of five generations of so-called EFTPOS machines.

Today the production is up to 2,700 housings per week for Racal and Geoff estimates that 75 per cent of the EFTPOS credit card terminals in the UK come from BEC