Case Study: Mach One Engineering achieves reduced cycle times and increased capacity with Vero Software's Edgecam Waveform

Mach One Engineering - Customer Case Study

Mach One Engineering, an ISO 9001‑accredited engineering subcontractor serving the satellite communications sector, needed to cut cycle times and push beyond traditional milling limits without compromising quality. Its skilled machinists were initially cautious about using much deeper cuts and higher feeds, but demand for faster, more efficient machining made a step change necessary.

By adopting Edgecam’s waveform roughing strategy, Mach One is using the cutter’s full flute length with a constant chip load and variable stepover to maintain an optimal width of cut. The change has delivered measurable gains—cycle time for an aluminium 4G amplifier casing fell from 2h05 to 1h36, feed rates in key parts rose (e.g., 2.4 → 4.5 m/min and 2 → 5.4 m/min), and depths of cut increased (e.g., 4mm → 15mm)—while also improving surface finish, extending tool and machine life, reducing noise and increasing production capacity.

Mach One Engineering

Chris Bentley

Managing Director