Creative Edge Master Shop gains efficiency with ProNest nesting software

Company overview: Creative Edge Master Shop

Creative Edge Master Shop is a pioneer in the application of waterjet technology, with the first and largest US waterjet operation dedicated to architectural interior applications. Creative Edge’s skilled team of designers, engineers, and technicians utilize 10 specialized waterjet machines to deliver award-winning spaces for its clients. The company specializes in concept flooring applications such as terrazzo, stone medallions, architectural metals and signage, and artistry in resilient design. Today, they are recognized as one of the nation’s leading providers of architectural waterjet fabrication.

Challenge: Programming designs was too time-consuming

Harri Aalto, Partner and Vice President of Creative Edge, guides the company’s creative direction. Once he completes his elaborate designs, they are passed on to the CAD/CAM department. The CAD/CAM department then turns his vision into reality.

After all the artistic detail is transferred into CAD drawing format, those complex CAD files – with every detail – are imported into the nesting software. There the files are converted to NC code and sent to the shop floor for the waterjet cutting process.

As demand grew for their work, Creative Edge realized processing the CAD files into NC code was taking too long. The programming system they used was tedious and very time-consuming. The company needed a software solution that would decrease programming time and maximize efficiency.

Solution: ProNest software increases efficiency

ProNest^® software delivered the functionality Creative Edge needed at the right price, with the added benefit of being easy to use. Plant Manager Shep Brown described how the decision process led the team to choose ProNest.

How CAD/CAM software works

CAD (computer-aided design) uses computer programs to draw the exact part or object that is needed. This results in a detailed 2D or 3D model.

The CAM (computer-aided manufacturing) part of the software directly communicates with and controls the machine tools used in the manufacturing process – including the CNC. The CAM software prepares the CAD file for cutting and machining.

In plate cutting operations, CAM software performs the critical function of nesting. Nesting is the efficient placement of multiple part geometries onto a given surface area.

The CAM software outputs NC (numerical control) code that can be read and understood by the CNC control, where it is converted into electrical signals that control the entire cutting process. From there, the NC file must be processed by the CNC, and instructions must be given to the cutting system and each of the various machine components before parts can be cut.

The CNC is basically an advanced industrial computer with internal motion and machine control software and a variety of inputs and outputs to control the drive motors, cutting systems, height controls, and other tools that might be mounted on the cutting machine. The CNC takes its orders from the machine operator and CAM software, converting the orders into perfectly timed electrical signals that control all functionality.

ProNest software

ProNest is an industry-leading CAD/CAM nesting software designed for advanced mechanized cutting. It offers the highest level of cutting expertise and provides a single solution for all profile cutting needs – including plasma, laser, waterjet, and oxyfuel. ProNest’s powerful, high-yield nesting is designed to supercharge cutting operations, enabling fabricators and manufacturers to increase material utilization, boost productivity, lower operating costs, and improve part quality.  

ProNest’s intuitive screens and a wide variety of helpful features make it easy to learn and use. Its faster, fully automated interface can reduce programming time from hours to minutes, while specialized cutting techniques can reduce total cut time by up to 50%.

ProNest is designed to work with virtually any ERP, MRP, or MES program. These integrations can extend ProNest’s efficiencies more broadly across the organization.

Unlimited access to technical support, training, and software updates is included with ProNest, ensuring every user gets the most value from their ProNest software.

ProNest software for waterjet systems

Waterjet cutting is an erosion-based process that uses extremely high water pressures – 4137 bar (60,000 psi) or higher – to cut material. Used with or without an abrasive, waterjet systems excel at very precise cutting of a wide range of material, with no heat-affected zone.

Fabricators and manufacturers use CAD/CAM nesting software to simplify the waterjet operator’s job and increase productivity. ProNest software supports parameters such as abrasive flow and control, kerf commands, cut speeds, cut heights, pierce types (wiggle, dynamic, stationary, or circle), pierce heights, time, and pressure.

Business impact: Jobs processed in minutes, not hours

Creative Edge has gained significant efficiency by switching to ProNest. ProNest can open an artistic CAD file and automatically section off each tile to be processed on the waterjet in a matter of minutes – an operation that used to take hours.

ProNest processes jobs that used to take between 30 minutes and 8 hours using the old software in just 5 to 10 minutes – saving from 25 minutes to nearly 8 hours on each job. An entire stone medallion can be opened in ProNest and each tile type will automatically be batch-nested in one master program.

Building off the successful ProNest implementation, Creative Edge is planning even more innovative programming techniques to further utilize ProNest in the future.

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