Industry

Precision engineering / Job shop

Country

Switzerland

Software

Siemens NX CAM · Siemens 840D

Duration

2 weeks

Post-processor development and validation for new 5-axis machining centre

The situation

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.

What GFE did

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.

Results

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.

Why GFE for CNC programming

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.

Have a CNC programming backlog or a new machine to integrate?

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Contact us

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Head office

30, Estrady, Warsaw, Poland 01-932

Phone: +48 798 763 604

For general enquiries: info@gfe-solutions.com

For sales enquiries: inquiry@gfe-solutions.com

Back office

201/203, Kharkivske shose,Kyiv, Ukraine 02121

Email: info@gfe-solutions.com

Phone: +38 098 237 0047

Our customers

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.

 

Christian Menke

CEO V. KRANZ GmbH, Dülmen

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.

Daniel Ilge

Head of Technology & Product Management at WALDRICH COBURG GmbH

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).

Frank Pfister

CEO of CVS engineering GmbH

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.

Dr. Thomas Bauer

Chief operating officer and member of the Board of DIENES Apparatebau GmbH

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.

Sebastian Schuelke

Managing Director at SICON GmbH

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.

Lukas Jochimek

Technical Manager at Schauenburg Maschinen- und Anlagen-Bau GmbH

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