Case Study: DeltaCAD Ltd achieves right-first-time, 9-day aerospace tooling with Vero Software's VISI

Delta CAD Collaboration produces tooling right first time

DeltaCAD Ltd, a Devon‑based CAD/CAM start-up founded by Dean Challis, partnered with tooling specialist Casting Support Systems to produce aluminium tooling for a carbon‑composite aircraft seat shell for a major airline. The challenge was to convert and adapt a customer’s Unigraphics NX model into a manufacturable tool—removing undercuts and adding blend radii—while meeting strict aerospace weight‑reduction goals and a tight delivery schedule.

Using VISI Modelling to tolerant‑ly edit non‑native data and VISI Machining for CAM, the team programmed optimized toolpaths and ran lights‑out machining on XYZ 1060 VMCs with specialised cutters. The multi‑insert tool was manufactured and assembled in nine days, delivered a “right first time” carbon‑fibre part weighing 5.25 lbs with virtually no split line, and delivered predictable, efficient production that exceeded expectations.

Delta CAD

James Head

Director