en.Wedoany.com Reported - German marine engine and generator manufacturer Everllence SE (formerly MAN Energy Solutions) has reduced roughing operation time by 60% and shortened the manufacturing cycle for each part by several weeks after applying PTC Creo CAM software and the High-Speed Machining (HSM) extension module in its CNC programming process.
Everllence SE provides propulsion, decarbonization, and efficiency solutions for the marine, energy, and industrial sectors, with over 140 business units globally and approximately 15,000 employees. The parts manufactured by the company include large components such as two-meter-long connecting rods. Due to their large size and high raw material costs, only one prototype can be produced for each part, requiring absolute reliability of the machining path to avoid rework, damage to parts or machine tools, and waste of time and materials. Previously, traditional roughing paths required long machine tool times, increasing production costs and reducing competitiveness against low-cost suppliers.
Since Creo NC was already part of Everllence SE's workflow, the NC programming team decided to adopt the High-Speed Machining (HSM) extension module for Creo Parametric. This module applies 3-axis high-speed machining paths directly within the PTC Creo CAD/CAM environment, eliminating the need to export models to external manufacturing solutions, reducing data conversion steps, and avoiding the risk of associativity loss. The HSM extension module features include basic drilling, 3-axis trajectory milling, 3-axis high-speed roughing, rest roughing, finishing, and rest finishing sequences, as well as constant load scanning in roughing sequences—equivalent to the functionality provided by high-priced third-party solutions—and adaptive feed rates.
By applying these 3-axis milling capabilities to the roughing process, Everllence SE's NC team generated more consistent and predictable tool paths, directly improving the quality and standardization of the production process, and defining this goal as "zero part defects." After applying the HSM extension module, the roughing operation time for the parts analyzed in the case study was reduced by 60%, and the manufacturing cycle for each part was shortened by several weeks. With the company producing hundreds of parts annually, the cumulative impact of reduced roughing time is significant in terms of cost and capacity.
The High-Speed Machining extension module is one of the options in the PTC Creo production machining portfolio, which also includes Prismatic & Multi-Surface Milling, Production Machining, Complete Machining, and Advanced High-Speed Machining extension modules. All extension modules require a Creo Parametric license and are designed to keep the manufacturing workflow within the same environment, from modeling to CNC programming and part inspection.
All extension modules also feature associative NC process planning (utilizing manufacturing notes and tooling fixture libraries), manufacturing process documentation generation, GPOST NC post-processor generator, and ModuleWorks-based material removal solutions.
Everllence SE's case is also applicable to large high-value-added part manufacturers in Brazil, such as those in the marine, oil and gas, energy, and capital goods industries. Reducing roughing time without sacrificing machining path reliability is a direct way to lower machine tool costs, avoid rework of expensive parts, and gain competitiveness. By integrating PTC Creo CAM programming directly into the PTC Creo modeling environment, the HSM extension module maintains associativity between the 3D model and the machining path, helping to reduce programming errors on critical parts.
The results achieved by Everllence SE, including a 60% reduction in roughing time and weeks saved per part, reinforce the practicality of PTC Creo CAM as a tool for manufacturing large parts. The company is already evaluating expanding the use of the HSM extension module to other machine tools and areas.
