Industry
Precision engineering / Job shop
Country
Switzerland
Software
Siemens NX CAM · Siemens 840D
Duration
2 weeks
A precision manufacturer installed a new 5-axis machining centre and immediately encountered a critical problem: the generic post-processor supplied with the CAM system produced unsafe output for multi-axis moves. The issues included incorrect RTCP activation sequences and unsafe retract behaviour on 5-axis trajectories. The machine could not be used for production safely. From the day of installation, the investment was generating cost without output, and the client had no internal capability to develop a machine-specific post-processor.
GFE developed a machine-specific post-processor for the Siemens 840D control from scratch, building it against the actual kinematics and controller behaviour of the installed machine. The post-processor was validated against 11 test geometries covering the full range of motion scenarios relevant to the client’s production — including simultaneous 5-axis moves, indexed positioning, and RTCP activation. All override options and configuration parameters were documented for the client’s own programming team to allow independent maintenance going forward. The client moved from blocked production to validated, running programs within two weeks.
11 geometries
validated
Safe RTCP
correct on all 5-axis moves
Zero rework
first part within tolerance
2 weeks
blocked → production-ready
We went from blocked production to running parts in two weeks. That was crisis management.
Programs are written and validated inside the client’s own CAM environment — using their software, file structure, and naming conventions. No separate system, no format conversion.
Each project is handled by programmers with direct experience on the relevant platform — Siemens NX, SolidCAM, Mastercam, or STUDER.
All programs are collision-checked and validated in Vericut before reaching the machine. This eliminates first-part scrap and reduces setup time on the shop floor.
All team members communicate in English. Senior programmers also speak German, enabling direct coordination with production and quality departments at client facilities in DACH.
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Our company produces safety-relevant welding assemblies for the chemical and pharmaceutical industry.
Due to the fact that it has become increasingly difficult to find good engineers and designers for our design department at our location in rural Münsterland, we set out at the end of 2018 to look for new external solutions in the service market.
I really appreciate GFE’s flexibility and openness for new challenges. They are not afraid to start a new journey.
If I think about the external circumstances of the project we started together, we reached a learning curve and relating results that I did personally not expect.
We required additional capacity and professional support for our R&D Team especially for a new product development.
And GFE Solutions offers capable support by very well-educated engineers. High professionalism. On time delivery and great communication (native German speakers).
We are the company in constant need for plants for research or pilot projects of our clients. Last year we were working over the order in the field of medical technologies, which we succeeded to realize, including thanks to efforts of GFE Solutions team.
We were in need of help with our design department ressources and we had to move fast, internal ressources were not available and GFE was able to help quickly and competent. GFE works with dedication to the very needs of its customers, has a variety of specialists and has offered a fair price on a transparent basis.
We were looking for additional engineers to expand our construction capacity. You seemed to be a young, motivated Team and except your professional expertise, your personal commitment made me confident to work with you. The cooperation has been seamless and very productive from the start. We are happy with the results.
GFE Solutions is a specialized engineering services company. Our engineers are mainly from Eastern Europe – to our customers we offer onsite- and offsite-engineering-services. All our specialists speak and write fluently English, some of them German and other languages.
Phone: +48 798 763 604
For general enquiries: info@gfe-solutions.com
For commercial requests: inquiry@gfe-solutions.com
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