Case Study: Next Intent Inc. achieves faster, more reliable high-speed roughing for Mars Rover components with 3D Systems' GibbsCAM VoluMill

GibbsCAM Enables Rover Exploration Vehicle Parts Go to Mars for the Third Time

Next Intent Inc., a San Luis Obispo machine shop that grew from making rover wheels for Spirit and Opportunity to a 34-employee aerospace supplier, was contracted to produce seven part numbers for NASA’s 2020 Mars Rover. The work included a large, heavily pocketed Ti-6Al-4V mounting deck and a complex 7050-aluminum wheel restraint fitting with deep undercut pockets; JPL’s required multi-step roughing, intermediate stress-relief inspections, and extensive five-axis repositioning made the parts especially challenging to machine without distortion or tool interference.

To meet the requirements Next Intent used GibbsCAM five-axis positioning and VoluMill high-speed roughing. VoluMill’s constant-load toolpaths reduced chatter, tool and machine stress, and sped material removal, while GibbsCAM’s Cut Part Rendering, Remaining Material Change, Coordinate System from View, and easy operation reordering let programmers proof, adjust, and update individual operations quickly. The result was successful production of the complex rover components to JPL’s process, fewer machine issues and tool changes, and improved efficiency on demanding five-axis work.

Next Intent Inc.

Rodney Babcock

Shop President