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CNC Machining & 3D Printing: A Hybrid Approach to Precision Manufacturing

With recent advancements in 3D printing capabilities, it is becoming easier for manufacturers to use additive manufacturing to create parts from a wide variety of materials, including polymers like ABS, TPE, and PLA as well as carbon fiber composites, nylon, and polycarbonates. Even pricey metals like Titanium, Stainless Steel, and Inconel are becoming increasingly common in the world of additive manufacturing as well.

There is no doubt that the additive manufacturing space will continue to develop and grow in the coming years, but will it render subtractive manufacturing methods like CNC Machining obsolete? Absolutely not. In fact, precision CNC machining is likely more important to the additive manufacturing process than you may think, as a new process called “hybrid manufacturing” is quickly taking hold in the industry.

3d printing metal
3D printing of metal parts is becoming more common, but subtractive manufacturing is an important part of manufacturing precision additive parts.

Additive Manufacturing vs. Subtractive Manufacturing

Before implementing a hybrid manufacturing approach, it is important to understand the pros and cons of each method. Here is a quick breakdown of both additive and subtractive manufacturing, and the benefits and drawbacks of each.

Additive ManufacturingSubtractive Manufacturing
Adds material layers to create partsRemoves material layers to create parts
Slower process, better for small production runsFaster process, better for large production runs
Better for smaller partsBetter for larger parts
Rough surface finish that requires significant post-operation finishingMore definied surface finish with minimal post-operation finishing required
Less precise part tolerancesAble to hold extremely precise part tolerances
Cheaper material costsMore expensive material costs
Less material wasteMore material waste
Intricate details easier to createIntricate details can require complex programs and additional capabilities (5 axis)

Using CNC Machining to Create Precise 3D Printed Parts

Looking at the chart above, you will notice that one of the key differences between additive manufacturing and subtractive manufacturing is the surface finish and tolerances that can be achieved with each method. This is where a hybrid approach to additive manufacturing can be extremely beneficial.

As parts come off the printer, they can be quickly moved into a CNC machine with a program designed for part completion. The CNC machine will be able to get 3D printed parts down to the tight tolerances required by many industries and reach the desired surface finish. Advanced finishing tools and long reach, tapered tools from brands like Harvey Tool can easily machine the tight geometries of 3D printed parts, while extremely sharp diamond-coated tooling and material-specific tools designed for plastics and composites can work to create a beautiful, in-tolerance finished part regardless of the material.

long reach end mill
Long reach tools can easily machine hard to reach, intricate part details on 3D printed parts.

By designing a workflow like this in your shop, you can spend less time worrying about the precision of printed parts by adding in subtractive operations to keep material costs low, create less waste, and keep parts in tight tolerances for precision machining excellence.

Using 3D Printing to Increase CNC Machining Efficiency

If your shop is focused completely on subtractive manufacturing methods, you are probably thinking that there is no need for an additive option in your shop. Can’t a CNC machine create everything a 3D printer can, and in less time? Not necessarily. Again, by using the two methods together and taking a hybrid approach, you may be able to lower your manufacturing and material costs.

For example, you could machine the bulk of a part with typical subtractive machines, which would likely take a very long time using additive methods. Then you can go back to that part with a 3D printer to add intricate features to the part that may take complex programming and hours of planning on a subtractive machine. An impeller is a great example, where the bulk of that part can be machined, but the tricky fins and blades could be printed onto the part, and then finished back on the CNC machine.

3d printed metal parts
3D printed impeller waiting for finishing operations

The ability of additive machines to literally “add-on” to a part can also make for a cheaper approach to part design. Instead of using expensive materials like Inconel or Titanium to machine an entire part, portions of the part that do not require extreme heat resistance could be machined out of cheaper steel, while the heat resistant portions using expensive materials can be added later through additive methods.

Hybrid Manufacturing Machines

As hybrid manufacturing workflows become more popular, so do new hybrid manufacturing machines. These hybrid machines are all-in-one machines where both additive and subtractive manufacturing can be performed in a single setup. Many of these machines offer metal 3D printing as well as multi-axis machining capabilities, ready for even the most complex parts thrown their way. With a bit of customization, large-scale 3D printing machines or CNC mills can be retrofit to allow for hybrid manufacturing with add-ons from companies like Hybrid Manufacuring Technologies.

hybrid manufacturing machines
Example of a hybrid machine add-on from Hybrid Manufacturing Technologies, featuring 3D printing spindles and milling tools in the same machine carousel.

As manufacturing and design techniques get progressively “smarter” with CAM/CAD programs offering generative design and artificial intelligence, these hybrid machines could become a new standard in high-end machine shops working in advanced manufacturing industries like aerospace, medical, defense, and the mold, tool & die market.

Overall, in 2021 we are still early on in this new revolution of hybrid machining and advanced design methods, but it is important to understand the role that adding a CNC machine could have in your additive-focused shop, and vice versa. By combining additive and subtractive together, shops can mitigate the cons of each method and take full advantage of the benefits of having both options available on the shop floor.

Workshops for Warriors – Featured Customer

In 2008, Hernán Luis y Prado, a United States Navy officer, noticed his fellow service members looking for a successful path in life after service. Hernán decided he needed to make a change. He set out to make a difference for his fellow service members by starting Workshops For Warriors, a state-licensed, board governed, fully audited, nonprofit school. Its mission is to provide quality training, accredited educational programs, and opportunities for its students to earn third-party nationally recognized credentials to enable Veterans, transitioning service members, and others to be successfully trained and placed in their chosen advanced manufacturing career field.

We had the honor of speaking with Marine Veteran Scott Leoncini, an instructor at Workshops For Warriors, about the accomplishments and amazing work Workshops For Warriors does for our Veterans.

What does Workshops For Warriors offer for our Veterans?

Workshops for Warriors offers two primary tracks of training, both taught by Veterans: welding and machining, Scott explained. After choosing a track, students become a part of the 16-week accelerated program. Those with only a minimum of four months and one nationally-recognized certification can walk across the shipyards and gain employment. Workshops For Warriors remains committed to providing free training to Veterans who do not have access to living-wage jobs. U.S. Veterans often face challenges as they transition to civilian life, including significant barriers to civilian employment. In addition to the hard technical skills, our students are also learning soft skills such as attitude, communication, work ethic, teamwork, time management, problem-solving, critical thinking, and conflict resolution.

A proven path into a rewarding career can eliminate problems like unemployment, homelessness, broken families, and suicide. The problem of Veteran unemployment does not have easy, short-term solutions. Workshops For Warriors is uniquely positioned to expand proven innovative techniques to give Veterans marketable employment that will allow them to build careers and families. 

How did you find Workshops For Warriors and become an instructor?

After I left the Marines in 2009, after serving two tours in Iraq as a combat engineer, I desired an action-packed career. I thought my best option was to start a career in law enforcement. I got a job at a security company and worked there for a few years. During this time, a close friend of mine tragically passed away in a helicopter crash, leaving behind his pregnant wife. This made me reevaluate my current life with my wife and two children. I decided I didn’t need that action-packed career, and that my family comes before anything.

Another friend of mine actually told me about Workshops for Warriors and how it was giving him career skills in welding, and he talked about a machining program. When I showed up, I had no idea what was in store for me. I started learning all about CNC machines, and how to program and run these things. It was eye-opening and I was having a great time. After my first semester, I was asked to become a teacher’s assistant and I’ve been teaching here now for almost five years.

Where does your passion for teaching come from?

I love teaching Veterans and helping them transition so they don’t have to go through the same five years I did of, “What am I going to do with my life?” I’ve gone through the same situation a lot of the people coming to us are currently in.

I think that there are three fundamentals that anyone looking for a career or path can apply to their lives and be successful. You have to show up on time, you have to work hard, and you have to be willing to learn. I didn’t know anything about machinery when I first got into this field. When I went through it as a student myself, I applied those three things to my work habits, and now I’m an instructor. I had pigeonholed myself for a long time. But you have to recognize that there’s always something else, something up next and that’s what I want to help teach the Veterans who come through here.

What courses does Workshops For Warriors provide?

We offer many different courses, including CAD courses in Solidworks and CAM courses in Mastercam, and we offer welding courses for Gas Metal and Flux Cored Arc Welding. We also offer advanced training in Flowmaster Programming and Waterjet Operation, 3D Printing, and Robotics. With these courses, we offer many credentials to start a real career. The machining program is accredited by the National Institute for Metalworking Skills (NIMS). NIMS is recognized by the United States Department of Education. The welding program is accredited by the American Welding Society (AWS), which is the worldwide leader in certification programs for the welding industry.

Thanks to private donors, Veterans and transitioning service members are able to become trained and certified in our advanced manufacturing programs. Students can apply to enter one of our programs, or take specific classes that meet their needs.

What jobs have you seen Veterans acquire after Workshops For Warriors?

We have seen many success stories from Veterans once they leave Workshops For Warriors. One Veteran, in particular, visited us in search of direction in 2019. The machining program had one spot left for the semester, so he took it. He is now certified in machining and welding. He entered a job market that was struggling after his graduation. But he still had a job lined up with 5th Axis Machining in San Diego. His future plans are to own his own business to support his family.

How could people help support Workshops For Warriors?

They can donate directly to us on our website, or on our Facebook page. Or, people looking to help support us can reach out to us by email, [email protected], or by calling us at 619-550-1620, with any questions. We also accept equipment donations for each program, welding, and machining. You can also support us by following on Facebook, Instagram, Twitter, LinkedIn, YouTube, or our newsletter.

What advice would you give to anyone looking to start a career path?

After leaving the service, I fell into a depression. I kept thinking, “I’ll never be as good as I was back then.” It was hard to not have “Marine” be the primary part of my identity, so I became blinded by my obsession with still being the superhero kicking down doors. Don’t paint yourself into a corner. Be flexible and make sure to show up on time, work hard, and be willing to have an open mind and ready to learn. Test your comfort zone. When I left the service, I only knew how to be the man with the gun. Workshops For Warriors gave me a chance to be more than that – it gave me a direction in life. I now get to do what I love and help my fellow Veterans.

To learn more about Workshops For Warriors and their mission you can visit their website or follow them on Instagram, Facebook, LinkedIn or Twitter.

Save Time With Quick Change Tooling

Making a manual tool change on any CNC machine is never a timely or rewarding process. Typically, a tool change in a standard holder can take up to 5 minutes. Add that up a few times, and suddenly you have added significant minutes to your production time.

As CNC machine tool and cutting tool technology has advanced, there are more multi-functional tools available to help you avoid tool changes. However, sometimes it just isn’t feasible, and multiple tool changes are needed. Luckily, Micro 100 has developed a revolutionary new method to speed up tool changes significantly.

What is the Micro-Quik™ Tooling System?

Developed in Micro 100’s world-class grinding facility in Meridian, Idaho, the Micro 100 Micro-Quik™ tooling system is held to the same standards and tight tolerances as all of the Micro 100 carbide tooling.

quick change system with micro 100 boring bar

The quick change tooling system allows for highly repeatable tool changes that save countless hours without sacrificing performance. This system combines a unique tool holder with a unique tool design to deliver highly repeatable and accurate results.

Each quick change tool holder features a locating/locking set screw to secure the tool and a locating pin which helps align the tool for repeatability. Removing a tool is as simple as loosening the set screw and inserting its replacement.

removing tool from quick change system

During tool changes, the precision ground bevel on the rear of the tool aligns with a locating pin inside the tool holder. The distance from this locational point to the tip of the tool is highly controlled under tight tolerances, meaning that the Micro-Quik™ tooling system ensures a very high degree of tool length and centerline repeatability. The “L4” dimension on all of our quick change tools, as seen in the image above, remains consistent across the entire product line. Check out the video below for a demonstration of the Micro 100 Micro-Quik™ system in action!

Quick Change Tooling Benefits

The most obvious benefit to using Micro 100’s Micro-Quik™ Quick Change Tooling System is the time savings that come with easier tool changes. By using the quick change holders in combination with quick change tooling, it is easy to reduce tool changes from 5 minutes to under 30 seconds, resulting in a 90% decrease in time spent swapping out tools. This is a significant benefit to the system, but there are benefits once the tool is in the machine as well.

As mentioned above, the distance from the locational point on each tool shank to the tip of the tool is highly controlled, meaning that regardless of which type of tool you insert into the holder, your stick out will remain the same. This allows you to have confidence in the tooling and does not require additional touch offs, which is another major time saver.

assortment of boring bars with quick change system

By removing additional touch-offs and tool changes from your workflow, you also reduce the chances for human or machine error. Improper touch-offs or tool change errors can cause costly machine crashes and result in serious repairs and downtime. With the Micro 100 Micro-Quik™ Quick Change Tooling System, initial setups become much easier, allowing you to hit the cycle start button with total confidence for each run.

By making a few simple changes to your tool holding configurations and adopting the Micro-Quik™ system, your shop can save thousands in time saved, with less machine downtime and increased part production. To learn more about the Micro 100 Micro-Quik™ cutting tools and tool holders, please visit (URL here to quick change page).

KAD Models – Featured Customer

Established in 2012, KAD Models is a small, yet steadily growing prototype machine shop, which originated in the San Francisco Bay Area and has since opened its second location in Vermont. They have been a regional leader in the advanced manufacturing space for many years, and operate in close connection with other machine shops and related businesses like turning facilities, anodizers, welders, and more. KAD Models staff is comprised of diverse occupational backgrounds (e.g. mechanic, industrial engineer, blacksmith, etc.). Further, they have invested into their local community college and technical training programs to support an expanding talent pipeline for advanced manufacturing.

Brian Kippen is the owner & founder of KAD Models & Prototypes, Inc. Before launching KAD with model maker John Dove, Brian worked as the Director of Operations at A&J Product Solutions and a machinist at Performance Structures. Brian is drawn to the challenge of making design concepts into reality, and motivated by the ever-changing landscape of machining. Brian took time to speak with us about KAD Models, his experiences, machining techniques, and so much more.

KAD Models cnc machining a custom part

Can you give us a little background on how KAD Models was started?

I worked for a few years repairing automobiles, then following high school, I attended college for about three weeks. After some strong encouragement from my mom, I moved out west. I joined the Marines, broke both of my feet, and was honorably discharged. Then, I got my broken foot in the door at a machine shop and knew what I wanted to be when I grew up. After years of working as a machinist, I went into business with one of my previous employers. After a year and a half, the partnership degraded and I made the decision to buy out my partner.

It’s been really gratifying to see the business grow and get to know different types of customers as the shop’s reputation spreads. One of the reasons I wanted to start my own shop is that I really wanted to see the industry evolve in a new way, to better meet people’s needs. It’s been really great to see that decision and the investments I’ve made in building KAD pay off.

We produce approximately $1.5M of parts for 100+ distinct clients each year.  Since its founding in 2012, KAD has continued on a steady path of growth, adding staff, equipment, and clients without marketing or advertising. We build a broad range of products such as automotive drive axles, silicone cardiovascular valves, and fully functional consumer product models. Due to the nature of prototyping, no component is outside of the realm of possibility. 

What machines are currently in your shop?

We use Haas CNC machines. At our West coast facility, we have six machines, five vertical 4 AXIS machining centers with capacities up to 26” Y AND 50” X and one 5 AXIS universal machining center. At our East coast facility, we currently have two new CNC ONE 3 AXIS and one 5 AXIS universal machining center paired with a Trinity Automation AX5 robotic cell. I decided to get a 5 axis milling machine earlier last year because I felt we should invest before the absolute necessity arose. I’m excited about the creative options it opened up and it’s been fun to put it to good use. We are currently using both Fusion 360 and Surfcam software.

What sets KAD Models apart from the competition?

Our quick turnaround time of 3-5 days with our ability to tackle very complex parts sets KAD apart from a majority of manufacturers.

I also think our willingness to really dig in with the client and get to know what they need and why. We have a really creative team here at KAD and thrive at not only building complex parts, but helping industrial designers and engineers think through manufacturing, design, and usage requirements to build the simplest, most effective product we can. I’ve created prototypes before, just from a conversation with someone – not even a CAD drawing. It’s these types of interesting challenges that made me want to be a machinist in the first place and that keeps me engaged and excited day-to-day.

end mill machining metal

KAD Models is an innovative company. Can you speak about what innovations KAD makes?

Well, KAD works with some of the most innovative companies out there, across all kinds of industries: medical devices, aerospace, automotive, and consumer electronics. We help people at the forefront of innovation bring their ideas to life, so I’d say innovation is basically our bread and butter. As far as our innovations in process, as I said before, KAD has a really creative team. Since we are well known for prototyping and since prototype manufacturing need not follow all the common work holding rules, we break them on a daily basis.

What is your favorite part of your job?

I love the challenge of taking on seemingly impossible ideas and turning them into tangible things. I’m really satisfied when I can come home after a long day and have held the things I’ve made in my hands. I’m also really proud to be a business owner. It’s incredibly rewarding to see a team you’ve taught and grown to take on and be inspired by the same types of problems as you. It’s been really cool to see what we’ve been able to accomplish for our clients. My personal passion remains automotive.  KAD has reverse-engineered many no longer available automobile components and designed parts that upgrade vintage Datsuns.

assortment of prototype parts made by Kad Models

Why is high-quality tooling important to you?

In prototyping, you often get one chance in order to make deadlines. High quality and high-performance tools allow you to get this done without question. Given 95% of our tooling is either Helical or Harvey, I would say that high-quality tooling helps us out on a daily basis. We also use High Efficiency Milling (HEM) techniques, which Helical is optimized for. We find with long cutters and with deep pockets, HEM is almost a must.  Often though, on shallow areas, it’s overkill.  As with salt, there can be too much. 

cnc machined metal wine rack

If you could give one piece of advice to a new machinist what would it be?

Fail fast and fail often. Then learn from your mistakes. 

I think the biggest thing is getting to know other machinists, learning other methods, and being open to alternative ideas. It’s important to keep your mind open because there’s always more than one way to machine something. One of the things I’ve found most rewarding about running my own shop is getting to set the tone of how we work with other shops and adjacent industries. I’m really passionate about the manufacturing community as a whole and I’m glad blogs like this exist to help draw connections amongst us.

Also, don’t be afraid to challenge the status quo. I love working with new machinists because they bring different ideas to the table. That’s really important for innovation and to keep us all moving forward.

Feel free to check them out at www.kadmodels.com or on Instagram @kadmodels or stop by their west coast shop in California or new east coast location in Vermont.

Machining Advisor Pro Updated With New Improvements

Harvey Performance Company is excited to announce that Machining Advisor Pro, a cutting edge resource for generating custom CNC running parameters, has been updated with new features and improvements with the release of version 1.5.

Thousands of users have enjoyed the benefits of using Machining Advisor Pro (MAP) to dial in their running parameters for their Helical Solutions high-performance end mills, and with version 1.5, the Harvey Performance Company team has made customizing your speeds and feeds easier than ever. Much of the work done on MAP version 1.5 was the direct result of excellent user feedback, including some of the most innovative updates to the user experience since the launch of Machining Advisor Pro in 2018.

The new improvements to MAP include:

Improved Speed and Feed Sliders (Desktop)

The speed and feed sliders in the “Recommendations” section are now percentage-based. This allows users to more precisely adjust their running parameters while fine-tuning numbers for increased production or longer tool life. Previously, users could adjust their speed and feed values with dials, but without an exact measurement of the increase or decrease. With the new sliders, users can be more accurate, adjusting their speed and feed values by +/- 20% in one percent increments. Users can also type in percentage values to automatically adjust the sliders to their desired number.

machining advisor pro

Locking Depths of Cut

Inside of the “Parameters” section, users will now see a new button that allows them to lock their depths of cut. With this new feature, users have more control over the customization of their running parameters. In the past, the radial and axial depths of cut would adjust dynamically with each other based on the user adjustments to one of the values. Now users can lock the radial depth of cut (RDOC) and adjust the axial depth of cut (ADOC) without affecting the RDOC value, and vice versa.

Machining Advisor Pro Update

Enhanced Summary Section (Mobile)

On mobile devices, users will now see an enhanced “Summary” section at the completion of their job. The summary section will now include key metrics like material removal rate (MRR), as well as important parameters that apply to trochoidal slotting toolpaths. The summary section for chamfering toolpaths has also been updated to better reflect the necessary parameters for those tools.

Machining Advisor Pro Mobile

Smoother User Experience

In MAP version 1.5, users will be greeted with a much smoother user experience throughout the application. Due largely to user feedback, the Harvey Performance Company team has been hard at work to make sure that the major pain points within the application have been addressed. Much of the feedback centered around the “Tooling” section and the “Material” section and significant improvements have been made to each.

In the tooling section, MAP will now automatically select a tool for you if you enter a valid EDP once you navigate outside of that section. If an invalid EDP number is entered, the intrusive error message has been removed and now will display “no results found” in the drop-down menu.

In the material section, MAP requires that a material condition be selected in order to generate accurate running parameters. In the past, this was not immediately clear and could lead some users to believe that the application was malfunctioning. In version 1.5, once a user leaves the material section without selecting a condition, a message will display in the material section to alert users of the missing material condition.

Open in MAP from HelicalTool.com

On the new HelicalTool.com website, users can now import a tool into MAP from the Tool Details page. Users reach the Tool Details page by clicking on a SKU in a product table, or searching for an EDP in the search bar. Once on the Tool Details page, users can select “Open in Machining Advisor Pro” under the Resources section, and MAP will open in a new window and import the tool’s information directly into MAP.

Helical MAP suggestion


Users will see these updates immediately upon their next log-in to the application on a desktop computer and will need to ensure their app is updated to the latest version from the App Store or Google Play to see these changes reflected on mobile.

To get started with Machining Advisor Pro, click here to create an account.

To stay up-to-date on all of the latest improvements and news on Machining Advisor Pro and the Harvey Performance Company brands, join our email list.

If you have any feedback or questions about MAP, please contact Harvey Performance Company at [email protected].

Harvey Performance Company Partners With GibbsCAM

January 7, 2020 (Rowley, MA) – Harvey Performance Company is proud to announce a new partnership with GibbsCAM, a powerful single interface CAM system developed by 3D Systems. GibbsCAM offers solutions ranging from simple 2-axis milling and turning to complex Multi-Task Machining, making them a great partner for the Harvey Performance Company family of brands.

As a result of this new partnership, GibbsCAM users can expect to see new Harvey Tool and Helical Solutions end mill libraries immediately available within GibbsCAM as a new plugin. This plugin will be included with all new releases of GibbsCAM, and will be available once users update their software to the latest version. In the future, users can expect additional tool libraries containing specialty profile tools, holemaking/threading tools, and tooling from Micro 100.

GibbsCAM users interested in accessing these new tool libraries can visit our FAQ page to learn more.

GibbsCAM Tool Library illustration

Key GibbsCAM and Harvey Performance Company Customer Benefits:

  • Harvey Performance Company tool libraries optimized for GibbsCAM users
  • No download required – all tooling is available directly in GibbsCAM in the plugin menu
  • New educational and technical content for machinists and programmers

“GibbsCAM has been a great partner for us,” said Jeff Rauseo, Manager – Digital Marketing, Harvey Performance Company. “By working with their software team to develop a new plugin built specifically for GibbsCAM, we are able to immediately offer accurate tool models to every GibbsCAM user with no downloads or imports required.”

“Having the Harvey Performance Company tool libraries available in GibbsCAM has been a welcome addition to our software,” said Israel Klain, Director of Engineering – GibbsCAM, 3D Systems. “The GibbsCAM community truly appreciates the partnership, and it supports our goal to continuously provide them with more efficient solutions for their metal cutting needs”


About 3D Systems
3D Systems provides comprehensive 3D products and services, including 3D printers, print materials, on-demand manufacturing services and digital design tools. Its ecosystem supports advanced applications from the product design shop to the factory floor to the operating room. 3D Systems’ precision healthcare capabilities include simulation, Virtual Surgical Planning, and printing of medical and dental devices as well as patient-specific surgical instruments. As the originator of 3D printing and a shaper of future 3D solutions, 3D Systems has spent its 30 year history enabling professionals and companies to optimize their designs, transform their workflows, bring innovative products to market and drive new business models. For more information visit: www.3dsystems.com

About Harvey Performance Company
Harvey Performance Company strives to offer unique and innovative products to solve industries’ most challenging machining requirements. Its distinct brands, Harvey Tool, Helical Solutions, and Micro 100, serve specialty needs and markets with a shared commitment to delivering high quality friendly service, providing comprehensive product support, and treating customers, suppliers, and shareholders in a way that builds strategic, strong, products and superior service. The brands offer a broad range of products and services that help support machinists, engineers, and CNC programmers while giving their shops a competitive advantage. Harvey Performance has a proud history of doing business the right way – offering fast and enduring relationships. For more information visit www.harveyperformance.com.

Axis CNC Inc. – Featured Customer

Axis CNC Inc was founded in 2012 in Ware, Massachusetts, when Dan and Glenn Larzus, a father and son duo, decided to venture into the manufacturing industry. Axis CNC Inc has provided customers with the highest quality manufacturing, machining, and programming services since they’ve opened. They specialize in manufacturing medical equipment and have a passion for making snowmobile parts.

We sat down with Axis CNC Inc to discuss how they got started and what they have learned over there years in the manufacturing world. Watch our video below to see our full interview.

How to Advance Your Machining Career: 8 Tips From Machining Pros

Since we began shining a light on Harvey Performance Company brand customers via “In the Loupe’s,” Featured Customer posts, more than 20 machinists have been asked to share insight relevant to how they’ve achieved success. Each Featured Customer post includes interesting and useful information on a variety of machining-related subjects, including prototyping ideas, expanding a business, getting into machining, advantages and disadvantages of utilizing different milling machine types, and more. This post compiles 8 useful tips from our Featured Customers on ways to advance your machining career.

Tip 1: Be Persistent – Getting Your Foot in the Door is Half the Battle

With machining technology advancing at the amazing rate that it is, there is no better time to become a machinist. It is a trade that is constantly improving, and offers so many opportunities for young people. Eddie Casanueva of Nueva Precision first got into machining when he was in college, taking a job at an on-campus research center for manufacturing systems to support himself.

“The research center had all the workings of a machine shop,” Eddie said. “There were CNC mills, lathes, injection molding machines, and more. It just looked awesome. I managed to get hired for a job at minimum wage sweeping the shop floor and helping out where I could.

As a curious student, I would ask a million questions… John – an expert machinist – took me under his wing and taught me lots of stuff about machining. I started buying tools and building out my toolbox with him for a while, absorbing everything that I could.”

One of the best things about becoming a machinist is that there is a fairly low entry barrier. Many machinists start working right out of high school, with 12-18 months of on-the-job training or a one to two year apprenticeship. Nearly 70% of the machinist workforce is over the age of 45. The Bureau of Labor Statistics is predicting a 10% increase in the machinist workforce with opportunities for 29,000 additional skilled machinists by 2024, so it is certainly a great time to get your foot in the door.

Tip 2: Keep an Open Mind – If You Can Think of It, You Can Machine It

Being open-minded is crucial to becoming the best machinist you can be. By keeping an open mind, Oklahoma City-based company Okluma’s owner Jeff Sapp has quickly earned a reputation for his product as one of the best built and most reliable flashlights on the market today. Jeff’s idea for Okluma came to him while riding his motorcycle across the country.

“I had purchased what I thought was a nice flashlight for $50 to carry with me on the trip. However, two days in to the trip the flashlight broke. Of course, it was dark and I was in the middle of nowhere trying to work on my bike. I’m happy to pay for good tools, but that wasn’t what happened. Not only was there no warranty for replacement, there was no way to fix it. It was just made to be thrown away. That whole attitude makes me angry. When I got home, I decided I was going to put my new skills to work and design and build my own flashlight, with the goal of never running into an issue like I had on my trip ever again. I started by making one for myself, then four, then twenty. That was four years ago. Now I have my own business with one employee and two dogs, and we stay very busy.”

An awesome side benefit to working as a machinist is that you have all the resources to create anything you can dream of, like Jeff did with Okluma.

machining career

Image courtesy of Okluma.

Tip 3: Be Patient – Take Time to Ensure Your Job is Setup Correctly before Beginning

The setup process is a huge part of machining, but is often overlooked. Alex Madsen, co- owner of M5 Micro in Minnesota, has been working in manufacturing for more than 11 years. Alex is also a part owner of World Fabrication, and owns his own job shop called Madsen Machine and Design. Alex has spent countless hours perfecting his setup to improve his part times.

“It is certainly challenging to use little tools, but the key is to not get discouraged. You should plan on lots of trial and error; breaking tools is just a part of the game. You may buy ten end mills and break six, but once you dial one in it will last the rest of the job.

You should also make sure to put extra time and effort into understanding your machine when working on micromachining jobs. You need to know where there is any backlash or issues with the machine because with a tiny tool, even an extra .0003” cut can mean the end of your tool. When a difference of one tenth can make or break your job, you need to take your time and be extra careful with your machine, tool inspection, and programming before you hit run.”

Tip 4: Effort Pays Off – Long Hours Result in Shop Growth

Success isn’t earned overnight. That is especially true in the machining world. Becoming a good machinist takes a great deal of sacrifice, says Josh from Fleet Machine Co. in Gloucester, MA.

“Opening your own shop involves more than learning how to program and machine. You also need to be willing to sacrifice some of your free time by working long hours to build your business from the ground up. Being a great machinist is important, but you also need to understand the basics of business, and you need to be able to sell your service and maintain a certain level of quality to keep your customers coming back.”

Working hard is a common theme we hear from our featured customers. Brothers Geordan and Nace Roberts of Master Machine Manufacturing have similar advice.

“We often need to work odd hours of the day to maintain the business, but we do it in a way that makes sure we have our family time. There are many times where we will go home, have dinner and hang out with the family, and wait until they are all sleeping to go back to work until two or three a.m. We will get back home later that morning to sleep a little and have breakfast with the family and send them on their way before heading back into the shop.” Starting and growing a business takes time. Every machinist starts from the beginning and through hard work and determination, grows their business.

Liberty Machine cnc mill

Image courtesy of Liberty Machine Inc.

Tip 5: Utilize Tooling from Quality Manufacturers – All Tooling Isn’t Created Equal

When it comes down to it, tooling is singlehandedly the biggest choice you will make as a machinist. Grant Hughson, manufacturing engineer at Weiss Watch Company who works as a manufacturing instructor in his spare time, reflected on the importance of tooling.

“Tool to tool accuracy and performance is vital in this business, especially with our extremely tight tolerances. High quality tools make sure that we get the same performance time after time without needing to scrap parts. This saves us valuable time and money.”

While opting for cheaper tooling can appear to be beneficial when just starting out, before long, machinists are losing time and money because of unpredictability. Jonathan from TL Technologies echoed this point, saying:

“We feel that if we invested so much in these high-end machining centers, it would be criminal to put insufficient tooling and holders into them. We found that by selecting the proper tool with the appropriate sciences behind it we have been able to create products with a cost per cut that is not only competitive, but required to stay current. By keeping the quality as high as possible on the part making side of things, we’ve insured as much ease and reliability into our downstream process as we could. Quality tooling also provides predictability and added safety into the workflow. High-quality carbide tooling is the lifeblood of the business.”

https://www.instagram.com/p/B1Gu33ngo8x/

Additional Thoughts Regarding Boosting Your Machining Career With Tooling:

Don’t Cheap Out

  • “The additional cost is always worth the payoff in the end knowing that you have a tool that will produce quality parts and shave valuable minutes off your cycle times. The slightly higher cost of the Harvey/Helical product is small change compared to the long term cost savings associated with their performance” – Seth, Liberty Machine

Consistency is Key

  • “We know the performance we are going to get from the tools is consistent, and we can always rely on getting immaculate finishes. While using the Harvey Tool and Helical product, we can confidently walk away from the machine and come back to a quality finished part every time.” – Bennett, RIT Baja SAE

Superior Specialty Tools

  • “One of the greatest things that I’ve experienced over the past year and a half is flexibility. We’ve asked for some specific tools to be made typically, the lead times that we found were beyond what we needed. We went through the Helical specials division and had them built within a couple of weeks. That was a game changer for us.” – Tom, John Force Racing

“Having high quality tooling like Helical is essential. Helical tools help us maintain a much higher machining efficiency because of the outstanding tool life, while also achieving more aggressive run times. In addition, we are able to consistently keep high tolerances, resulting in a better final product.” – Cameron, Koenig Knives

Tip 6: Get With the Times – Join the Social Media Community

Social media is a valuable tool for machinists. With ever-increasing popularity in networks such as Facebook, LinkedIn, Twitter, and Instagram, there will always be an audience to showcase new and unique products to. We asked a few of our featured customers how they incorporated social media into their machining and the benefits that come along with it.

“A lot of our sales come through Instagram or Facebook, so I would recommend those platforms to anyone who is trying to start a business,” Jeff from Okluma said. “We have also had a lot of success collaborating with others in the community. Typically it is something we couldn’t do ourselves, or they couldn’t do themselves, so we share the labor and collaborate on some really cool items.”

Tip 7: Value Your Customers – Always Put Them First

“In the Loupe’s” featured customers repeatedly emphasized the importance of putting customers first. It’s a simple concept to master, and pays off immensely. Repeat customers tell you that you are doing something right, said Brian Ross, owner of Form Factory.

“We have kept our customers happy and consistently deliver parts on time, so we get a lot of repeat business. Word definitely gets around on how you treat people so we try to treat everyone with respect and honesty which is key to running a good business.” Jeff from Okluma takes great pride in his customer service, saying “we only sell direct to consumers through our website so we can control our lifetime warranty. It has worked really well for us so far, so we have no plans to change that right now. I care more about our customers than any retailer is able to.”

man examining machined part for machining career

Image courtesy of MedTorque.

Tip 8: Never Stop Learning – Ask Questions Whenever You Can

Hopefully some of these tips from our featured customers stuck with you. To leave you with a quote from of Seth Madore, owner of Liberty Machine, “Don’t stop learning. Keep your ears open and your mouth shut,” “That old guy in the shop has likely forgotten more than you will ever learn. The amount of tools in your Kennedy box doesn’t mean you’re a good machinist. Some of the best toolmakers I knew had small boxes with only the common tools. Learn how to excel with limited resources. Ask questions, and own up to your mistakes.”

Harvey Performance Company Partners With SolidCAM

April 4, 2019 (Rowley, MA) – Harvey Performance Company is proud to announce a new partnership with SolidCAM, the industry leaders in integrated CAM software. SolidCAM software runs directly inside the popular SOLIDWORKS and Autodesk Inventor CAD programs, with seamless integration and full tool path associativity.

As a result of this new partnership, SolidCAM users can expect to see updated Helical Solutions tool libraries, new Harvey Tool and Micro 100 tool libraries, and more engaging technical content in the coming months. Users will see the immediate benefits of this new partnership during the upcoming Live Machining Webinar titled “The Science of Cutting” hosted by SolidCAM on April 10. This webinar will feature live machining with Helical Solutions tooling, utilizing SolidCAM’s iMachining technology. Interested viewers can register for this event here.

Key SolidCAM and Harvey Performance Company Customer Benefits:

  • Harvey Performance Company tool libraries optimized for SolidCAM users
  • New educational and technical content for machinists and programmers
  • The opportunity for CAM and tooling companies to learn from each other, bettering the overall customer experience from tool selection to programming.

“SolidCAM and Harvey Performance Company are a great fit as partners,” said Jeff Rauseo, Senior Marketing Specialist – Strategic Partnerships & Applications, Harvey Performance Company. “We are especially excited to work with them on their iMachining technology, which utilizes many of the same High Efficiency Milling techniques and benefits that we share with our customers regularly.”

“SolidCAM is honored to embark on this partnership with Harvey Performance Company,” said Ken Merritt, Director of Partner Projects & Senior Applications Engineer, SolidCAM. “The Harvey Performance Company tooling brands are a great fit with iMachining, providing high performance chip removal that does not limit the performance of SolidCAM’s revolutionary iMachining tool path.”


About SolidCAM
SolidCAM provides a powerful, easy-to-use, integrated CAD/CAM solution that supports the complete range of major manufacturing applications, including iMachining 2D and 3D, 2.5D Milling, High Speed Surface Machining, 3D Milling/High-Speed Machining, Multi-sided Indexial 4/5 axis Milling, Simultaneous 5 axes Milling, Turning, advanced Mill-Turn including Swiss-Type CNCs and WireEDM. SolidCAM’s patented, unique revolutionary iMachining technology saves 70% in CNC machining time and more and extends tool life dramatically. The iMachining Technology Wizard provides a reliable partner in automatically determining speeds and feeds and other machining parameters. iMachining provides unbelievable savings and increased efficiency in CNC milling operations, translating into profits and success. All SolidCAM customers worldwide, who bought iMachining, are enjoying immense savings! For more information visit www.solidcam.com.

About Harvey Performance Company
Harvey Performance Company strives to offer unique and innovative products to solve industries’ most challenging machining requirements. Its distinct brands, Harvey Tool, Helical Solutions, and Micro 100, serve specialty needs and markets with a shared commitment to delivering high quality friendly service, providing comprehensive product support, and treating customers, suppliers, and shareholders in a way that builds strategic, strong, products and superior service. The brands offer a broad range of products and services that help support machinists, engineers, and CNC programmers while giving their shops a competitive advantage. Harvey Performance has a proud history of doing business the right way – offering fast and enduring relationships. For more information visit www.harveyperformance.com.

Okluma – Featured Customer

Okluma is a small manufacturing business located in Oklahoma City focused primarily on creating high-quality flashlights that can stand up to the most extreme conditions. The company was founded in early 2015 out of owner Jeff Sapp’s garage, and has quickly gained a solid reputation as one of the best-built and most reliable flashlights on the market today.

We were able to steal a few moments of Jeff’s time to interview him for this Featured Customer post, where he shared his thoughts on topics like the importance of customer service, the reason to use higher quality tooling, and his transition into the world of CNC machining.

To get started, how did you first get involved in manufacturing?

In high school I actually worked in a machine shop. This is where I got my first exposure to big machines and manufacturing. I worked at the shop until I graduated, doing simple things like sweeping the floor and running errands. The work wasn’t very exciting, but it did give me some really good exposure to the world of machining. Every now and then one of the machinists would let me help out with a part, but that would be rare. I did manage to save up enough money to buy a small mill and lathe, which I took with me when I went off to college.

During college and after graduation, I made a living by writing software, which I did successfully for 15 years. Eventually I got tired of writing software after I had spent more than a decade in that space, and I wanted to try something new. I had picked up small jobs and worked on personal projects over the years, so I decided to enroll in a machine shop school in Oklahoma City to learn more about manufacturing and becoming a machinist, and graduated from there with a renewed sense of what I wanted to do. Technical schools are a great way to pick up new skills and advance your career. The manufacturing technology program at the Francis Tuttle Technology Center here in Oklahoma City was great and the instructors there, Dean and Julia, are talented and very patient people.

okluma

Did your background in writing software help you transition into CNC programming?

Absolutely. It was a tremendous help to understand some very strange programming concepts that came with writing software, and it all translated very well into CNC programming. These days, CNC machinists and programmers need to be as knowledgeable about the software and programs as they do the tools and parts, so having a background in software programming or development certainly translates well to the world of CNC machines.

Where did the idea to start Okluma stem from?

After graduation from the machine shop program, I took a few weeks off and went on a long, off-road motorcycle trip across the country. I had purchased what I thought was a nice flashlight for $50 to carry with me on the trip. However, two days in to the trip the flashlight broke. Of course, it was dark and I was in the middle of nowhere trying to work on my bike. I’m happy to pay for good tools, but that wasn’t what happened. Not only there was no warranty for replacement, there was no way to fix it. It was just made to be thrown away. That whole attitude makes me angry.

When I got home, I decided I was going to put my new skills to work and design and build my own flashlight, with the goal of never running into an issue like I had on my trip ever again. I started by making one for myself, then 4, then 20. That was 4 years ago. Now I have my own business with one employee and two dogs, and we stay very busy.

okluma

What does your current product offering look like?

For our products, I currently have two flashlights models (the DC1 and DC2) and we are working on some cool new projects for 2019. With battery and LED technology advancing like it has, there are some interesting applications, way beyond just flashlights, that haven’t been possible until recently. Stay tuned for more information on those by following us on Instagram.

What do you think separates an Okluma flashlight from the competition?

The basic values behind Okluma all stem from me simply wanting a nice tool that won’t break easily and will be supported by the manufacturer. I offer a lifetime warranty and stand firmly behind that. I want an Okluma flashlight to last forever so you will never have to buy another flashlight.

The quality and hardiness of a flashlight is important to many outdoors types, homeowners, and collectors, but we also sell lots of our flashlights to the military and police. If their light goes out in a tough situation it could be really bad, so we have to make sure our flashlights can be dependable above all else. Like they always say, you get what you pay for. Our flashlights aren’t going to be the cheapest, but we stand behind them with our warranty and pride ourselves on the quality and reliability.

okluma facility

What sort of machines and software do you have in the shop?

Right now I have the old standards like a Bridgeport mill and an old LeBlond lathe, as well as my CNC machines – a Daewoo Lynx 220LC CNC Lathe and a Doosan DNM 4500 CNC Mill.

For software, I use Autodesk Fusion 360 for the mill, and I write the G-code by hand for the lathe. I was more familiar with the lathe, so I had an easier time writing my own code for it. Getting Fusion 360 for my milling has been a huge help.

okluma cnc mill

Have you been using the Harvey Tool and Helical Solutions tool libraries in Fusion 360?

Yes! The tool library in Fusion 360 was a huge help for me. To be able to get the right tool and not model things incorrectly probably saved me a lot of broken tools. That was a big reason why I came to Harvey Tool and Helical for support in the first place.

It was cool to come from the software community, where we collaborated on a lot of open-source projects, and see companies like Autodesk opening up their software to manufacturers like Harvey Tool and Helical for these great partnerships.

What sort of operations/parts do you create on the lathe versus the mills?

As you can imagine (being a cylindrical shaped part) most of the flashlight manufacturing is done on the lathe. For a while I had been making them all by hand, until we got the CNC lathe. While most of the work is done on the lathe, for the more intense pieces we have to drill and tap and do some different slotting operations. We also drill and tap the clip holes for all of the flashlights, so the CNC mill is huge for those operations.

As Okluma started to grow, we realized that we had a huge bottleneck doing our secondary operations by hand on the manual milling machine. We solved that problem by buying the Doosan mill to help with secondary operations, but you still have to know how to use it to make it worth the purchase!

I was completely in the dark on the CNC milling side of things at that time, as I was much more familiar with the lathe. I actually called Harvey Tool with a few questions, and the Harvey Tech team really held my hand and walked me through all of the things I needed to know, which was huge. I also used the Machining Advisor Pro application to generate speeds and feeds for my Helical end mills. MAP helped save me a lot of broken end mills and increased my production times.

okluma

You are using almost exclusively Harvey Tool and Helical for milling operations on your Doosan VMC. Why is purchasing quality tooling important to you?

I can try to do things on my own and eventually get it, but it costs me money on broken tools and it costs me my time, which is even more valuable. I could go that route with any number of different tooling manufacturers, but the fact that I can call Harvey or Helical and get an answer to my questions the first time, usually in a few minutes, and know it will work is hugely helpful. I don’t really look at the cost of the tools so much, because I just know they work and I know I will get the support I need to make my milling operations a success.

Can you remember a crucial moment when Harvey Tool or Helical technical support helped you to be more productive?

As we try to get more creative with our designs, we plan to rely heavily on Harvey and Helical to explore some of these new applications. We actually build our own tool to work on the flashlights, and we are using Harvey and Helical exclusively to machine that. At first, I was making the tools in two operations; I was doing a radius on top and then flipping the part over to create a radius on the bottom. I was having a hard time lining it up. We moved the second radius on the first operation, and used an undercutting tool and everything matched up perfect. I wasn’t really sure how to do it, but I called you guys and you figured it out with me! We have some cool projects coming up which we are planning to rely on Helical tools for, but people will have to stay tuned for that one!

okluma

What have been some of your keys to success for your growing sales?

Good customer service is key. We are one of the few companies that will offer a lifetime warranty. I know there are a lot of flashlight collectors, and we can make fun stuff for those guys, but I want people to really use our flashlights and scratch them and do ridiculous things with them. We have had people use a flashlights in crazy ways (like as a hammer) but we will still fix them under our lifetime warranty. I don’t really care what people do to our flashlights, I just want them to always work.

We can also overnight replacement flashlights for professionals who rely on them for work, so they never have to be without one. That is huge for our customers in the military or in law enforcement who rely on our flashlights as an essential tool in their day-to-day lives.

Do you have plans to expand into retailers, either online or brick and mortar stores?

We only sell direct to consumers right now through our website so that we can control our lifetime warranty. It has worked really well for us so far, so we have no plans to change that right now. I care more about our customers than any retailer is able to.

I’ve noticed that you have gathered a rather large social media following. How has social media helped shape your business?

A lot of our sales come through Instagram or Facebook, so I would recommend those platforms to anyone who is trying to start a business. We have also had a lot of success collaborating with others in the EDC (Every Day Carry) community where makers are creating knives, wallets, keychains; anything you would carry on you “every day”, hence the name. We have collaborated to make flashlights out of other people’s materials, let other shops refinish our flashlights, and things of that nature. Typically it is something we couldn’t do ourselves, or they couldn’t do themselves, so we share the labor and collaborate on some really cool items.

I think social media is especially great for manufacturing because a lot of younger people don’t even know all this crazy cool stuff that is going on in the industry. I was lucky enough to see it first hand at a young age, but so many others never get the chance. It is awesome to share our work and try to inspire some of the younger generation to make their own products and participate in the world of manufacturing.

okluma


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