Millennium Patterns, Leeds, Alabama, produces wooden and plastic metal casting patterns on a CNC machine that costs only one-fourth as much as those normally used for the task. When the pattern industry switched to CNC several years ago, most companies purchased small machining centers that cost in the area of $80,000 including programming software. Millennium Patterns, when it started operations one year ago, decided instead to purchase a lighter-duty CNC machine designed specially for wood and plastic machining. Co-owners Joel Busler and Jim Collins said that with less overhead than its competitors, the company was able to reach full capacity within a few months of opening its doors by providing its customers high quality patterns at a very attractive price.

Patterns are used in the foundry industry to produce sand molds that are used to cast the actual part. Patterns for parts that are produced in quantities of thousands require metal patterns that must be produced on machining centers. On the other hand, wood or plastic patterns are used for parts that are produced in smaller quantities because of their lower cost. Just a few years ago, these patterns were typically produced on lathes and bandsaws by highly skilled operators who often spent days or even weeks finishing each piece. The problems with this approach were 1) it was very labor-intensive, 2) accuracy depended on the skill of the worker and 3) a mistake made it necessary to scrap the piece and start over.

The two owners of Millennium Patterns had each been in the pattern business for about 12 years when they decided to start the firm. Their primary concern in starting the business was the need to finance an expensive machining center that they felt they had to have to be competitive in the business. That’s why they were pleasantly surprised, shortly before going off on their own, to discover a machine designed specially for lighter duty machining at a much lower price.

The Techno Series III gantry router from Techno, Inc., New Hyde Park, New York is similar in function to a CNC machining center. At about $20,000 including software, the machine is considerably less expensive than a machining center and designed for lighter duty work. Yet, it provides the same surface finish and accuracy as a machining center. Its working area of 29.5 inches by 21 inches with a Z-axis height of 11 inches, is larger than nearly all machining centers in the under-$100,000 price range. The machine can handle virtually any type of material although it is limited to relatively small depths of cut in ferrous and other tough-to-machine materials. In fact, one key feature is the Techno servo system's ability to cut 3D continuous contours at up to 200 inches per minute, far faster than most machining centers.

Millennium purchased the machine and its owners were able to teach themselves to operate it in a day or so. This was largely because the Mastercam CNC programming software, from CNC Software Inc., Tolland, Connecticut, supplied with the machine was easy to learn. Although originally designed for metal working, Mastercam is also well-suited for industrial design models because of its ability to generate the most complex contours with little programming effort. Mastercam includes IGES, DXF and CADL converters so that geometry can be uploaded from many CAD systems.

The machine proved to be ideally suited to pattern making. When they first opened their doors, they didn’t have any work and used the machine to machine 12 foot long signs that helped draw attention to their business. As business started trickling in, they demonstrated that they could produce patterns to the same high level of quality that is achieved by more expensive machine tools. The Techno machine's .0002 inch resolution and repeatability and 0.003 inch/ft. absolute accuracy are the result of several features inherent to the table, such as the use of ball screws and servo motors. For example, anti-backlash ball nuts permit play-free motion that makes it possible to produce accurate circles and inlays.

Once they proved that they could match the quality of larger shops using more expensive machines, business really started to take off. The firm was able to offer lower prices than many of its competitors because it didn’t have the burden of having to pay off an expensive machine. Another factor that helped keep costs down was the many years of programming and machining experience possessed by both of its owners. It was also often able to offer faster delivery times than the larger pattern shops. Within a few months, Millennium Patterns was operating at 100% capacity.

The majority of the company’s business so far has come from the construction industry. (One customer is Allen-Robbins Architectural Metals, one of the nation's largest ornamental and historic restoration suppliers). For example, they have produced patterns for stairways, balconies and lamp posts. One of their most interesting projects was a 14 foot long fluted support for a hotel restoration project in Selma, Alabama. On this project as in many others, the Millennium owners traveled to the site to take measurements and make a reproductive mold to insure the accuracy of their pattern. The ability to produce high-accuracy patterns at a reasonable cost has in several cases made it possible to produce one of a kind or very low volume castings that would not have been economical using earlier methods.

In approximately 3000 hours of operation, Millennium Pattern has had no problems with the Techno machine. This is partly due to the strength and rigidity of the table, which is constructed from extruded aluminum profiles that provide easy clamping capability. The machine also has four ground and hardened steel shafts and eight re-circulating bearings in each axis. This rolling contact ensures longer life and greater rigidity during the life of the system because of the reduced wear as compared to ACME screws and nuts or rack and pinion systems, which have a sliding friction contact.