Case Study: Kavia Tooling achieves standardised, error‑free multi‑part machining with Vero Software's Edgecam

Edgecam Programs Merged into Single Machining Files with 1.5-Million Lines of Code

Kavia Tooling is a 15‑person mould maker in Burnley producing around 80 injection mould tools a year. The company faced long, error‑prone setup times and complex NC management when machining multiple components—often with many separate CNC programs—that limited machine uptime and consistency across operators.

Working with Edgecam and Hexagon, Kavia developed a customised "Merge" workflow that combines multiple Edgecam programs into single large CNC files (up to 1.5 million lines), integrates Zoller presetter tooling data, and uses a CMM zero‑transfer fixture to set offsets offline. The result is standardised, error‑reduced production: setups that used to take a day can take an hour, apprentices can perform tool setting, cutting tools are minimised, and machines run longer unattended shifts—significantly increasing productivity and confidence on the shop floor.

Kavia Tooling

Mark Cole

Production Director