December 2007 Edition

CAD/CAM

Ford is Driven Lately

Sharing a last name with an auto giant isn't intimidating for a Louisiana native

Ford might be a big name in Michigan, but in Westlake, LA, Don Ford has found he is making a name for himself because of his machining expertise. Westlake, with a population of 4,668, won't rival Detroit, but that hasn't prevented Ford, owner of Ford CNC, from following his passion: manufacturing.

Still a one-man shop, he's invested in the right equipment and software to get the job done. He's learning to use these tools to the max while relying on inexpensive resources to get over the bumps.

"Actually, what I'm doing is a hobby that is drifting toward a business," Ford said. "In a few years I hope to move from my regular job to a full-time shop."

Ford works as an operator at a local chemical manufacturing plant. His 14 12-hour days on and 14 days off schedule gives him time to develop automated work processes for the used Okuma milling machine he purchased. As could be expected in a start-up business, Ford CNC has had its highs and lows, but the business has taken an uptick since he installed Mastercam CAD/CAM software at the end of 2006.

"When I started out – with an old Bridgeport that I replaced with the Okuma – I discovered software really helps machine programming. Programming by hand was tedious, time consuming, and labor intensive. It could take forever."

He said that although he knew software was of assistance, finding the right one was tough [for another view of this, see the From the Shop Floor column in this issue – Ed.].

"My first choice started well, but things went in the wrong direction. I stuck with it for a few years, longer than I should have. A friend of mine recommended Mastercam, and I took his advice."

Mastercam is a product of CNC Software, Tolland, CT.

With Mastercam, Ford said he doubled his business volume since he can program parts faster. Quality also increased since the toolpaths improved surface finish. He said he plans to continue building up his applications knowledge and CAD/CAM programming skills to improve his business.

However, with his investment in the mill and software, there's not much left to invest in formal training – not that he would have the time. Instead, Ford is following a time-honored tradition of calling on his friends for help.

He'll Get by With a Little Help from His Friends

Friends, Don Ford has a lot of them. Back in his younger days, Ford spent time motorcycle and drag racing. Before he developed a need for a steady income, he took a job with a friend who owned a race company. He said he got hooked on designing and machining custom parts. He still does that, creating oil pans of his own design or machining a turbocharger kit drawn and toolpathed in Mastercam, given to him by another friend from his motorcycle racing days. Ford also makes specialized industrial pieces, like Teflon parts he recently cut for a company that makes analytical equipment.

One of Ford's friends is Ken Cartwright, owner of Cartwright Co., Portland, OR. Cartwright is finicky, according to Ford, and won't recommend a product until he is 100 percent comfortable with it. It was Cartwright who advised Ford about the value of Okuma mills and Mastercam software.

Owner of a shop much larger than Ford's, Cartwright benefits from consultations with tool vendors such as Western Tool. Cartwright then passes information to Ford for his benefit.

Workholding difficulties are an example of the shoptalk between the two friends. Cartwright recommended the Albrecht APC Milling Chuck, which he'd been using for several years, to Ford. Ford bought one and has used it since.

Friends have also kept Ford from getting in over his head. He passed work on a complex part to another friend because it was beyond the capability of Ford's equipment.

Basic training came bundled with Ford's Mastercam software seat. He said he was concerned about the package's learning curve for a neophyte like himself. The distributor who ran the class said that with Ford's experience, he was a candidate for advanced training. Ford said he plans to take it some day, but until then his distributor has answered questions when Ford ventures into unfamiliar territory.

Remote Assistance

Ford's Mastercam reseller is about 75 miles from his shop, but the distance isn't a problem.

"If I am having trouble with a part, we both get on the Internet and log onto Net Viewer," Ford said. "He can either look at my screen or I can look at his. He can run mine or I can run his. When I'm starting to struggle and I need to get work out, it's like he's sitting right beside me. This will be even more important when my business becomes full time."

Ford is educating himself, too, through books and articles. But, reading isn't enough. It's always better to see a demonstration than to read about it.

He said he learns quicker if he can read about it and then see it demonstrated. Streaming Teacher – www.streamingteacher.com – is a site that does that. The site was started by a Mastercam reseller who posted libraries of demonstration videos related to Mastercam and AutoCAD. Ford liked what he saw and subscribed. Users can sign up to have unlimited access to a library of courseware by the quarter, half year, or full year.

Ford gets help from people he has never met in person. The assistance comes from forums and message boards. For example, at the 2006 IMTS show in Chicago he saw thread milling demonstrated.

"I'd never done thread milling," he said. "So I went to the eMastercam Web site – www.emastercam.com – and found a Q&A forum."

He posted a question and checked for a response the next morning.

"Somebody replied and gave me helpful suggestions."

With ingenuity and advice, Ford is growing his business. During the first half of 2007, there were several months when Ford CNC brought in more income than his regular job. As word spreads about his quality and speed, he's building a backlog. Mastercam

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