The manufacture of marine models and moulds poses special challenges because of the size of the final parts. One company using Delcam's CADCAM software to overcome these challenges is Lanulfi, which is based in Monticello Count Otto, near Vicenza, in Italy. It has replaced traditional modelling techniques for the construction of physical prototypes and for the production of moulds. The company also uses the software to manufacture other large-scale plastic products, mainly for the automotive sector.

Marco Lanulfi, son of founder Lino Lanulfi, explained that a good pattern and a good mould is the key to the quality of the final product. Because of the size of models and the moulds, the overall design must be split into a number of more manageable parts in practically every case. These are subsequently assembled into the full-scale model or mould. In addition to the good quality surfaces that are needed in each section, perfect matches are required between the various components. Any discontinuities would require costly manual repair.

Lanulfi uses Delcam's PowerSHAPE CAD software to import designs from its customers, to make any modifications necessary to improve manufacturability, and to divide the overall design into the various sections. The sections are then machined in polyurethane using programs generated in the PowerMILL CAM system, before being assembled into the complete pattern. From this model, the mould that will be used for the production of the boat is produced in glass fibre-reinforced resin.

"PowerMILL is able to perform very accurate machining even when using continuous five-axis operations,'' claimed Mr. Lanulfi. "This makes it possible to obtain high-precision components and surfaces with a high-quality finish.''

"Another key factor is the flexibility given to the users, who can quickly edit the tool paths, adapting them to any last-minute requests. Also important is availability of postprocessors optimised for the machines we use.''

"PowerMILL also allows us to visualise the cutting process on the computer, so that, when we go to the machine, we have the confidence that everything will work as planned,'' he added. "This allows us not only to save time and material, but also to make better use of our machine resources, in particular to work during the night, without the need for supervision.''