- Surfware
Infobox Company
company_name = Surfware, Inc.
company_type = Private
foundation =1988
location =Camarillo, California , USA
key_people = Alan Diehl, Founder; Stephen Diehl, President and CEO
industry =CAD /CAMSoftware
products = SURFCAM Velocity Powered by TrueMill
homepage = [http://www.surfware.com/ www.surfware.com]Mission Statement
Surfware, Inc. is dedicated to continuous innovation and the development of new technologies that increase our customers’ productivity and profitability. Our goal is to provide top-quality technology and customer service; it is also our goal to provide world-class solutions that allow our customers to gain a competitive edge in a global marketplace.
History
In 1950, Victor Diehl opened a mold shop in Southern California for machine tooling medical products. Throughout the 1950s, Victor Diehl supported his family through his focus on precision mold products for the medical industry. In the 1960s, Victor and son Alan invested in NC (Numerical Control) machines to expedite tooling of components for aircraft manufacturing. Ten years later, Alan and his brother-in-law Jack Epps, a physicist, built a smart NC machine powered by a mini-computer.
In 1980, Bryan and Larry Diehl, Alan’s sons, greatly influenced by the mathematical skills of their uncle Jack, joined the machining firm and wrote a UNIX program for surface modeling and machining. In 1988, Surfware, Inc. was formed by Alan and Larry, and SURFCAM was launched -- the first PC-based modeling and NC programming software to be offered commercially to the industry.
Over the next decade, SURFCAM’s features advanced along with the capabilities of the PC. Every release brought new firsts and functionality: first NURBS surface technology on a PC ; first PC-based four-axis simultaneous machining; first CAM system for 32-bit enhanced-mode Microsoft Windows, first PC CAM system with automatic rendering of blended surfaces; first to deploy new features in 2- and 3-axis rest machining.
In early 2000, Pat Patterson (Uncle Pat) with co-inventor Alan, began work on what would become the ground-breaking TrueMill technology, a completely new toolpath strategy that controls the load on the tool to significantly increase productivity (in some cases over 100%) and extend tool life for all materials, including aluminum, steels, titanium, Inconel and other exotics.
SURFCAM Velocity Powered by TrueMill was launched in 2005, with internal instructions on how to limit the maximum stepover to cut optimally everywhere along the toolpath on any part geometry. The software won Industry Week’s Technology Innovation Award. Since that time, in live demos and on customer sites, SURFCAM Powered by TrueMill has continued to excel.
Surfware Today
Surfware recently moved into a new 12,500 square-foot headquarters in Camarillo, California. In addition to a growing staff of 35 people, Surfware works with a strong network of domestic and international resellers who provide invaluable strength and teamwork for the organization. The company maintains its own suite of milling machines to test the latest developments and innovations its state-of-the-art TrueMill technology.
In 2008, Stephen Diehl, Alan’s eldest son, became President and CEO of the company. According to Stephen, “For almost six decades, my family and the Surfware team have focused on creating innovative, high-quality products that enhance the industries we serve. I am constantly amazed by the many beneficial uses that our customers have found for Surfcam and TrueMill. As the sole provider of the TrueMill technology that manages tool engagement to create superior toolpaths, we are committed to helping our customers become more efficient, profitable and successful.”
Products
SURFCAM Velocity 4 is a major new release of Surfware's flagship, world-renowned flagship CAM software.
2-Axis -- The highest performance, most cost effective 2-axis product.
3-Axis -- Efficient, reliable toolpaths on the most complex surface geometry with the highest quality surface finishes.
4/5-Axis -- True simultaneous 4 and 5-axis machining, full visualization and verification, enabling the NC programmer to move and control any combination of the machine's axes.
TrueMill -- The biggest advancement in milling since the personal computer was introduced to CNC programming.
Standard Features -- Including SURFCAM Lathe, Verification Machine Works, PlugIns and Solid Modeling.TrueMill
TrueMill is a significant milestone step in the long history of machining. TrueMill is the name for a patented set of discoveries centered on controlling tool engagement while machining a part of almost any type or material. By controlling the tool’s engagement with the material, TrueMill has repeatedly proven to greatly increase material removal rates (MRR), decrease cycle times and extend tool life. The research and discoveries that went into the development of TrueMill took place (and continue to occur) at the Camarillo, California-based CAM software company, Surfware, Inc.
In 2001, mathematician and Surfware R&D expert Pat Patterson was presented with the question, why can’t we create a toolpath where the tool engagement angle (TEA) or effective stepover does not change? He and Surfware co-founder Alan Diehl set to work on this problem and within one year had developed an early working version of TrueMill. Over the next several years, the pair went on to supervise the work of others in the firm, testing even more complex cases. In 2005, a patent application was filed. Co-inventors were listed alphabetically regardless of their actual contribution. Since that time, additional components have been added to the patent by filing a "continuation in part" application with the US Patent and Trademark Office.
As the science around TrueMill developed, so did the software implementation of the physics and mathematical principles behind it. In 2005, Surfware released SURFCAM Velocity Powered by TrueMill. Companies with machining applications worldwide embraced the technology with outstanding results, but there was still more work to do. With the release of SURFCAM Velocity 4 Powered by TrueMill, issues that limited some TrueMill functionality were solved, numerous enhancements were implemented, and early users have generated rave reviews.
TrueMill toolpaths are very different from other tool motion paths. All corners, all the sharp directional changes have been effectively eliminated. The tool never plows into a corner. The technology works on all part shapes. Rather than generating toolpaths based on a given stepover value and the shape of the geometry being machined, TrueMill manages tool-engagement angles to produce toolpaths that are far superior to anything on the market today. The net result is that much more aggressive cutting parameters can be used, resulting in dramatically reduced cycle times.
The core problem in milling has always been the inability to control the cutting tool’s engagement with the material. This makes it physically impossible to keep the load on the tool constant and forces machines to be run at far less aggressive cutting parameters than they are capable of, resulting in longer cycle times. TrueMill solves this core problem. The motion of the toolpath is designed with consideration for the in-process material boundary everywhere along the toolpath to ensure that the tool is never over-engaged. The toolpath does not require adjustment because the tool will never be buried in the first place. The toolpath stays as close as possible to the desired engagement angle without ever exceeding it.
TrueMill toolpaths are engagement-angle driven, not geometry driven. In other words, the shape of the geometry doesn’t dictate the flow of the toolpath. Rather, each cut is made such that the next cut can be made at the desired engagement angle. The part shape is ultimately produced, of course, but it doesn’t really become apparent until the final passes of the tool. Because of this smooth, flowing, engagement-controlled motion, SURFCAM Velocity 4 Powered by TrueMill can be run at feedrates, spindle speeds, depths of cut and stepovers that might at first seem impossible.
The current approach to high-speed machining involves taking very light cuts. TrueMill enables the machine to run at high speeds with much heavier cuts. Also, due to the even loads, there is less stress on the machine and the cutting tool. Tool life is actually extended while cycle times are reduced. These two concepts used to be mutually exclusive.
Specialized toolpaths are usually the result of treating a symptom of the problem, rather than solving the problem itself. With TrueMill, the core problem that produced all of these symptoms in the first place has been solved. Since there are no symptoms to treat, there is no need for multiple, gimmicky toolpath options. There is just one strategy that works in all cases. It even removes the distinction between pocketing and contouring or profiling. You just select your geometry and TrueMill knows what to do.
For any company machining a part, SURFCAM Velocity 4 Powered by TrueMill will make a dramatic difference to bottom line costs and profitability. With the ability to cut even the hardest materials at rates up to 100% faster, the doubling and tripling of tool life and “lights out” operation of even the most complex jobs, the positive effects ripple up and down operations and functions and include (but are not limited to):
Time savings (more parts can be created in less time)
Machine savings (more can be done on a less expensive machine)
Tool replacement savings
Time to market savings
Energy savings
Personnel savingsBecause TrueMill technology is useful to so many industries, in addition to software sales, Surfware will be providing custom solutions and offering turnkey solutions as well as partnering with vendors of complementary technologies to ensure that all users achieve maximum success.
TrueMill Benefits
No need for multiple pocketing routines
No sharp corners or abrupt changes in direction
Enhances the performance of any machining hardware (cutting tools, tool holders, machine tools, controllers)
Machine Tool & Cutting Tool life is extended
Works on any CNC milling machineFor the past twenty years, Surfware has been an acknowledged industry leader in producing world-class, innovative and user-friendly CAM software. That tradition continues today.
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