The best way to avoid these walls is to build the CAD and CAM application on the same 3-D database. This avoids the process of translating data from one format to the other, which could delay the project and increase the risk of errors. It also enables associative CAD/CAM usage, where modifications in the CAD geometry will automatically update the corresponding CAM programming.

By eliminating the communication gap between mold designer and NC programmer, the overall leadtime for a mold can be reduced. If the CAD and CAM applications have the same user interface—ideally via a single-window integration—a major improvement can be achieved: NC programmers on the shop floor can apply design-for-manufacturing operations in their own environment by editing the mold geometry as problems arise.
In principle, there are two ways to achieve these benefits:

1. The CAD/CAM software supplier develops its own “native” CAD application on the same 3-D database used for the CAM application.
The seamless integration is then possible; however, the investment to develop a complete CAD application may not be profitable, if the system supplier sells only several thousand CAD licenses per year. Also, it’s important to take into consideration that the supplier has to develop design-related functions—including analysis, PDM and geometry import capabilities, which moldmakers need to communicate with their customers.

2. Build a CAM application on the 3-D database of an existing mainstream 3-D CAD system.
Here, through single-window integration, all machining calculations are defined, calculated and verified in the same CAD environment. All geometries used for machining are fully associative with the mold design model. When the geometry of the mold design is modified, the CAM software enables the user to automatically synchronize all machining operations with the updated geometry.

An important tool for associativity is a powerful assembly mechanism. Here an assembly top-down approach is used, where the core of all components is the part to be manufactured and all other components like molds or toolpaths should reference to it. The assembly mechanism can update all references, when changes are made to the original design. Also, vice versa, any mold adaptations performed on the shop floor in the CAM software can be easily used by the designer to update the original project assembly.

This approach does not only ensure an efficient and easy-to-use NC programming, but also a cost-effective one for the CAM software supplier: He can focus his development resources to the CAM modules, and can leverage the CAD partner for part and mold design, and related functions—including all of the geometrical interfaces, mold fill simulation and additional analysis tools.