Computer-aided design and computer-aided manufacturing (CAD/CAM) are merging the design and production processes at LESER into a single workflow.  

Over the past decade or so, the German term “Industrie 4.0” has become a synonym for the Fourth Industrial Revolution, which is in full swing at LESER where the focus of digitalization is on transforming manufacturing processes. But the changes the digital transformation brings about have repercussions far beyond the way the shop floor is organized: For successful digitalization it is essential to integrate all design, production and planning systems.
This is why LESER has begun to implement computerbased programming of its complex, automated CNC-controlled machining equipment within the scope of the “LESER is digital” program. This includes full 3D modelling of each component or product as a “digital twin”. These activities are enabled by Computer Aided Design (CAD) and Computer-Aided Manufacturing (CAM).

Using 3D models of safety valves has been standard practice at LESER for years: As early as 1998, LESER created its first 3D model of a cast housing for its Type 526 safety valve. At that time, specifications for individual characteristics that were required for the many different variants of the valve were provided in a table on the 2D drawing; for example, customer-specific flanges, facings, or water drain holes. In the future, a unique CAD model will be generated for every single variant of a component which can then be used by the digital manufacturing software. To make physical components based on the digital models, the CAM software needs to be able to identify the geometry information generated by the CAD software so it can calculate the tool path for the machine tools.
This explains why the “CAD for CAM” project is such a long-term undertaking at the Technical Department. The project was launched in January 2020 and will be completed during the coming fiscal year. Its goal is to define principles for every single machinable component at LESER which can then be integrated into a unique CAD model.
This concept is being implemented in the new manufacturing cell (page 24) for large valves in the DN 250-400 / 10-16 inch range for the first time.
The Technical Department is generating around 700 new CAD models for valve bodies, double-flanged bends and change-over valve bodies for the manufacturing process of XXL-sized safety valves. These models will be the first ones used for digital manufacturing by the new manufacturing cell. In the future it will be possible to generate separate CAD models of all needed 3D variants in the system using variant data tables, and manage this information using SAP. A team of engineers is currently testing the required SAP modules called “Engineering Control Center” and “Model Processor”. Until the “Model Processor” tool for the CAD software Creo is rolled out in the spring of 2022, the CAD models for all components will be created manually.