Case Study: Rolls‑Royce achieves faster delivery and precise hub machining with 3D Systems (GibbsCAM & VoluMill)

Rolls-Royce Propels Business Growth with GibbsCAM

Rolls‑Royce Canada’s Marine division in Vancouver faced a critical deadline when it had to machine, assemble and deliver two controllable‑pitch propeller hubs for a ferry with only a two‑week drydock window. The small 30‑person facility received 5,800‑kg duplex stainless castings late from Sweden and confronted complex geometry, long tool extensions and tight radii that made traditional 2D programming too slow and risky—Swedish subcontractors estimated two months to machine the pockets.

The team adopted GibbsCAM 3D programming with the VoluMill option and brought in WestCAM support to develop optimized toolpaths; within two days they were productive and finished both hubs in just over a week. The approach maximized material removal, reduced chatter and improved tool life, produced highly repeatable fits (static balance errors of just seven and nine pounds), cut machining and assembly time by weeks, secured six follow‑on hub orders, and enabled successful sea trials.

Rolls-Royce

Dij Sahota

Service Manager at the Vancouver Facility