The right CAM Dramatically Reduces Programming Time for Tool & Die Manufacturer
Enmark Tool & Gage Co. | Fraser, Michigan, United States
Key Takeaway
Enmark Tool & Gage Co., a long-established precision shop, was preparing to expand into 5-axis machining to meet growing demands from its aerospace, and tooling and machine tool customers.
However, its existing CAM system lacked the capability to efficiently handle complex toolpaths, integrate fixtures, and scale with their programming needs. With a new machine on the way, Enmark needed an advanced CAM solution that its team could quickly adopt.
After implementing hyperMILL® CAM software, even before its new machine arrived, Enmark dramatically reduced programming time, improved workflow flexibility, and equipped its programmers to take on 5-axis parts with speed and precision.
Michael Cox, Co-Plant Manager at Enmark, shares how switching to hyperMILL® and investing in 5-axis machining dramatically improved the company's productivity and competitiveness.
Founded in 1951 and family-owned for three generations, Enmark Tool & Gage Co. has evolved from a small gage shop into a highly capable precision manufacturer serving the aerospace and machine tool industry. Based in Fraser, Michigan, Enmark has the rare capacity to handle a range of part weights from 6 lb to very large 10,000 lb components, all machined to tight tolerances of ±0.00025 inches in materials such as 6150 and Tool steel, iron, and aluminum.
Today, Enmark is doing something few others can claim. Leading OEMs and machine tool builders rely on Enmark to manufacture or retrofit their own equipment, entrusting them with jobs that demand precision, reliability, and large process consistency.
“With our previous software, it took 200 hours to program a part. With hyperMILL®, we completed the same part in just 50. We also cut the (number of) toolpaths down from 450 to about 130.”
Michael Cox, Co-plant Manager
The move to hyperMILL® and 5-axis
When Enmark Tool & Gage Co. made the decision to expand its operations into 5-axis machining, it became clear that their existing CAM software wouldn’t be able to keep up with the increasing complexity and tolerance requirements of their parts. To take full advantage of the new machine investment, Enmark began searching for a more advanced, flexible, and user-friendly CAM solution.
According to Mort Ogden, Sales Operations Manager, the priority was finding CAM software that could handle the wide variety of parts Enmark produces, while also instilling the confidence that the machine and the software would execute identical motions for precise collision checking. The search involved evaluating three to four different CAM systems. They first learned about OPEN MIND’s hyperMILL® through word of mouth and YouTube demo videos, which sparked further interest.
After in-depth evaluation, Enmark chose hyperMILL® largely because of its proven postprocessors, which were already tested and optimized for their newly acquired HERMLE C650, and its automation features. “Being able to use the hyperMILL®’s macros for setups and programming was a significant time saver, especially for complex jobs, and the automation capabilities promised to streamline repetitive processes,” said Chris Mikolaczyk, Enmark Lead Programmer. Combined with the reassurance that collision-checked toolpaths would translate exactly to the machine, all these factors made hyperMILL® the clear choice.
HERMLE C650 5-axis mill
Gear box housing on HERMLE C650
Furthermore, rather than wait for the new HERMLE C650 5-axis machine to arrive, Enmark began preparing early by installing hyperMILL® and conducting one month of R&D testing and part cataloging. This early implementation gave the programming team time to train, build model fixtures and risers, and develop toolpath strategies in advance. By the time the machine was installed, the team was already confident in using hyperMILL® and fully prepared to begin production.
“Our programmers had never used hyperMILL® before, but after just two days of in-house training, it came naturally to them,” says Michael Cox, Co-Plant Manager.
The structure and flexibility of hyperMILL® made it easy to create advanced toolpaths without requiring weeks of trial and error, making the transition to new CAM software incredibly smooth. The hyperMILL® system’s workflow aligned with the way Enmark approached part preparation and allowed the programmers to begin generating production-ready code almost immediately.
More importantly, hyperMILL® enabled Enmark to deliver measurable results, starting with a significant reduction in programming and machine cycle time. For example, the same part that took 200 hours to program with their older CAM now takes 50 hours—a 75% programming time reduction, as well as 25% decrease in machining time. They also managed to cut down on the number of toolpaths from 450, to about 130, explains Michael Cox.
Time savings were immediately visible
The first part they programmed in hyperMILL® was a complex housing, and the time savings were immediately visible. The software gave Enmark a new level of control and clarity in programming, helping to simplify previously time-consuming tasks and gain confidence in the machining process. Compared to its previous CAM system, hyperMILL®’s 3D toolpaths proved to be more efficient, safer with collision-free verification, easier to program, and fully editable. The results were consistently accurate, with predictable outcomes every time. In contrast, the previous software often behaved unpredictably, where even a small change could completely alter the toolpath. With hyperMILL®, accurate and fast toolpath verification became standard, ensuring both speed and reliability in production.
The new software didn’t just help them improve efficiency—it changed the way Enmark planned for future jobs. With strong early results and a growing number of parts suited for 5-axis workflows, Enmark quickly made the decision to purchase an additional hyperMILL® license.
By investing early in the CAM system, preparing ahead of machine delivery, and building internal confidence through training and early achievements, Enmark set itself up for success with 5-axis machining. hyperMILL® provided the required programming power, without any slow down during the transition to 5-axis.
Complex parts are efficiently programmed with hyperMILL® to meet tight tolerances.
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Machining confidence with VIRTUAL Machining
hyperMILL® VIRTUAL Machining (VM) played a crucial role in enabling Enmark to confidently program and machine complex parts accurately and safely. hyperMILL®’s integrated virtual machine environment enables Enmark to simulate real machine behavior with exact kinematics and postprocessor logic. This ensures that what is programmed on the screen behaves identically on the machine, which is ideal due to the high precision parts Enmark programmed. According to Chris, hyperMILL® VIRTUAL Machining allows him and his team to program the entire part with minimal changes once it reaches the machine, with most adjustments focused only on improving toolpath efficiency. Initially, this capability gave Enmark’s programmers the opportunity to quickly become proficient with the software and boosted their confidence in machining complex components. In an industry where the learning curve can often be long and steep, this advantage was significant. Enmark was able to begin producing parts immediately upon receiving the machine, avoiding delays and maintaining productivity.
“hyperMILL® VIRTUAL Machining has had a major impact on how we handle tight-tolerance components,” says Cox. “It helps with everything—setups, quoting, programming. We import fixture items or vises, calculate toolpaths, and make adjustments without restarting the entire process.”
For Enmark, which specializes in one-off, tight-tolerance components, hyperMILL® VIRTUAL Machining eliminated the trial-and-error typically associated with new 5-axis setups. The ability to import fixture items, simulate tool lengths, and validate entire sequences before cutting, significantly reduced the risk of tool collisions and setup errors. It also improved quoting accuracy, as the team can estimate cycle times and verify accessibility before cutting on the machine.
The impact has been particularly evident when using aftermarket machine components, such as a 90-degree head. hyperMILL®’s custom virtual machine environment has allowed the team to program complex angled features without writing manual NC code or worrying about compatibility with machine cycles. With confidence in the simulation’s accuracy, Enmark was able to run unattended shifts, knowing the NC code had been validated in advance.
“The Optimizer [enables] the table to rotate and tilt automatically. We have even drilled holes outside of the Y-axis limit—all within a single program,” says Michael. “If the VM says the program is good, our operator hits the green button and goes home. In the morning, the parts are done.”
The need for this capability became clear at the onset on a very first large part job for the Hermle C650, which exceeded the machine’s travel limits. The job required drilling holes on the outside diameter and machining features beyond the Y-axis stroke. By running the program through Optimizer, hyperMILL® automatically calculates safe table rotations and tilts to reach these areas without over-travelling the machine. This eliminates the need for a complex programming approach or return paths, allowing Enmark to complete the entire job in a single program. The result was hours saved in programming time and a machining setup that handles oversized parts efficiently and safely.
Overall, hyperMILL® VIRTUAL Machining gave Enmark the tools to expand into complex 5-axis work with precision, predictability, and peace of mind.
Simple, powerful strategies that unlock new business
The shift to hyperMILL® has opened new doors for Enmark. The team frequently uses advanced toolpath strategies such as 5-axis Halfpipe Machining, which provides new capabilities for winning new business.
“It lets us tackle parts we couldn’t machine before,” says Michael. “We’re now in markets we used to avoid because we weren’t competitive.”
Chris also appreciates the intuitive interface and control the software offers: “I love that I can surface using boundaries instead of trying to draw a containment box. It’s incredibly powerful for blending and re-machining.” Even 2D and 3D milling operations are exceeding expectations.
hyperMILL® 5-axis half pipe strategy used to efficiently program tube bending die.
Source: Enmark
“The software capabilities have been phenomenal. 2D milling is much easier than we anticipated, and the superb surface finish speaks for itself,” adds Cox. The team has also built a custom fixture library within hyperMILL®, enabling copy-paste of toolpaths and CAD data between jobs and work zones.
“We save hours on repeat setups.” Simple jobs now take 20 minutes and 3 – 4 hours can be saved on more complex jobs. I can transfer everything—toolpaths, fixtures, workholding—from one job to another in seconds,” added Chris.
The right partner for growth
Behind hyperMILL® software is a support team that, according to Enmark, makes a real difference.
“OPEN MIND support has been great. We get answers immediately, and often multiple options for solving a problem,” says Michael.
Previously, the programmers were often resorting to 3+2 strategies as a workaround, knowing there was likely a better 5-axis solution, but lacking the time to figure it out. Chris was able to simply send a SHOP Viewer file (read-only file with toolpaths and process data for review and simulation on the shop floor) directly to the support team, who quickly responded; “They respond with a better option sometimes within the day,” says Chris. “Feedback includes optimized toolpaths and better programming strategies.” This level of assistance has helped Enmark transition from time-consuming, limited strategies to efficient, true 5-axis toolpaths that deliver better results with reduced programming efforts.
The results: A 60% improvement in programming time, reduced scrap, and greater confidence at every stage of production. “Before, it would take operators ten hours per program, and now we can do it in three,” adds Michael.
On top of that, hyperMILL® has improved the part quality dramatically, due to collision detection and creating significantly cleaner toolpaths. Collision detection is crucial for large (and complex) components that Enmark manufactures. “We haven’t crashed a machine once since we’ve had hyperMILL®,” notes Chris.
hyperMILL® has reduced programming time by at least 60%, reduced scrap and given Enmark great confidence at every stage.
Source: Enmark
5-axis composite material guide
Source: Enmark
The parts coming off the machine are now 100% complete. In the past, even on CNC machines, many components required secondary grinding to achieve the desired finish. With hyperMILL®’s high-precision machining capabilities, Enmark has eliminated the grinding step. “We achieved a 13 Ra fine grind surface finish without any jig grinding,” explains Marty Dobson, Quality Control Manager. This was made possible by hyperMILL®’s sophisticated CAM functionality, which generates toolpaths with extremely fine resolution, enabling exceptional surface finishes directly from the milling process.
As Enmark continues to support some of the most demanding industries including manufacturing components for CNC machines themselves—hyperMILL® has become a core part of the company’s success story. Looking ahead, Enmark plans to expand the use of hyperMILL® across all machining operations, further enhancing their capabilities and strengthening their competitive edge.
View of Enmark Quality Lab – Enmarks reports that parts coming off the machine are now 100% complete.
CMM inspection of a forming press component – due to collision detection and significantly cleaner toolpaths, hyperMILL® has dramatically improved part quality.
Chris Mikolaczyk from Enmark shares how hyperMILL® and Virtual Machining helped accelerate their move into 5-axis machining. Even before the machine arrived, jobs were fully programmed and tested.
Today, Enmark benefits from reliable NC code simulation, reusable workflows, and high process safety without a single machine crash.
Chris Mikolaczyk, lead programmer at Enmark Tool & Gage, has over 25 years of CNC machining experience and 15 years of CAM programming expertise. After just two days of in-house training with OPEN MIND, Chris quickly transitioned to hyperMILL®, finding it far more intuitive and surface-driven than the line- and curve-based CAM systems he had used in the past.
In less than a year, he mastered the software, programming complex 5-axis parts that have helped Enmark gain new customers and stay competitive. Chris highlights how hyperMILL®’s VIRTUAL Machining allowed the team to simulate the real machine’s movements before their HERMLE C650 5-axis machining centers even arrived—making it possible to start production immediately without downtime. He also credits OPEN MIND’s responsive support for providing faster strategies and better programming approaches, enabling significant reductions in programming time and driving higher productivity across the shop.