Case Study: Taylor Forge Engineered Systems achieves rapid, precise Inconel header production for a solar power plant with 3D Systems

Forging Ahead with Solar Energy and GibbsCAM CNC Software

Taylor Forge Engineered Systems, a Kansas-based manufacturer serving petroleum, natural gas and nuclear markets, won a contract to produce Inconel headers for a 100+ MW solar power plant but faced major machining challenges. The parts required single-setup 4-axis machining with numerous small, angled holes held to 0.100" true position from three datums, and the shop lacked in-house CNC programming expertise—previously outsourcing NC work or spending eight to nine hours manually editing programs, which led to missed bids and limited quoting ability.

Taylor Forge implemented GibbsCAM alongside Autodesk Inventor and added a Haas VF11 4-axis mill, using features like Hole Manager, Cut Part Rendering, reliable post-processors and helical milling. Programming times fell from many hours to minutes or a few hours (e.g., holes programmed in ~20 minutes, full models and toolpaths in ~2 hours), cycle times were shortened, scrap risk reduced, and accuracy improved (worst-case hole placement was 0.007" from nominal). The upgrades expanded their quoting capability and brought measurable productivity and business growth.

Taylor Forge Engineered Systems

Kirt Stevens

Manufacturing Engineer