The Digital Path to Aerospace and Defence Machining – Webinar Series

In precision manufacturing, the gulf between programmed toolpaths and machine reality is shrinking profits, slowing development, and introducing risk on every contract. This 2025 four-part series is built for engineers, planners, and senior leaders who demand predictability, not guesswork.

Hosted by Dr. Rob Ward and delivered in collaboration with AMRC Machining Group experts, the series takes you on a structured learning journey — from foundational CAM challenges to the most demanding use cases in 5-axis blisk machining and ultra-large defence forgings.

Each session dissects real-world problems using Virtual Machining and DigitalCNC’s kinematic modelling, showing how to eliminate costly trial cuts, validate complex geometries, and make confident, data-driven decisions before the first chip is cut.

ENDED: Webinar One | Thursday 20th November 15:00 GMT

Conquering the Digital Gap: Advanced CAM, Virtual Machining and DigitalCNC for Precision Machining

Precision machining is defined by unforgiving materials, complex geometries, and non-negotiable quality demands. Even the most carefully programmed toolpath can fail on the shop floor due to the “Delta between CAM and CNC”—the fundamental mismatch between the theoretical model and the reality of the real world.

This introductory webinar breaks down the core CAM Challenges in Precision Machining. We will define the Industry Drivers pushing manufacturers toward digital solutions and provide a foundational understanding of the modern digital toolbox required to guarantee part quality and minimize costly physical prove-outs.

Learn how to leverage Virtual Machining to bridge the gap between design and production, ensuring precision and predictability from the very first cut.

Key Topics Covered

The Foundation: Industry Drivers & Toolpath Design

  • Industry Drivers: Identifying the forces shaping aerospace production (e.g., lightweight materials, Buy-to-Fly ratio, safety, and traceability requirements).
  • Toolpath Design: Foundational concepts in generating efficient and safe tool motion, focusing on strategies that maximize Material Removal Rate (MRR) while protecting thin walls and tight features.

The Critical Gap: CAM vs. CNC

  • Delta between CAM and CNC: The core problem—why the time and motion predicted in your CAM system rarely match the actual machine tool behavior. This covers issues related to machine kinematics, control limitations, and complex toolpath geometries.
  • Importance of Header Information: Understanding how crucial data—machining type and tolerance in NC program header—drives machine behavior and must be rigorously verified.

The Digital Solution: Predictability and Accuracy

  • Importance / Benefits of Virtual Machining: Moving from “trial-and-error” to “predict-and-verify.” The benefits of simulating the entire machining process offline to detect collisions, check tool engagement, and eliminate scrap before running the part.
  • Digital Toolbox: An overview of the essential software and systems required for modern NC shops, including simulation, post-processing, and verification tools.

Planning and Execution

  • Machine Selection: Factors governing the choice between 3-axis, 5-axis, and multi-task machines based on part geometry and material.
  • Time Studies: How accurate time prediction is achieved using virtual machining to provide reliable Time Studies for cost estimation and scheduling.

If you have any questions about this webinar or the series, please email info@digitalcnc.ai.

Hosted by CEO Dr Rob Ward

Expert Insight from our Guest Speakers

Emily Pickford – Technical Fellow
AMRC

Rich Bonnell – Innovation Fellow
AMRC

Webinar Two | Thursday 12th February 15:00 GMT

High-Speed, High-Value: Mastering Adaptive Milling Strategies

“High-Speed Machining Validation – When Every Second Counts”

Perfect For:

  • Tooling suppliers proposing high-feed endmills and dynamic strategies
  • Application engineers supporting aerostructure and thin-wall machining
  • Machine tool sales teams demonstrating high-speed capability
  • CAM programmers optimizing roughing and finishing cycles

What You’ll Learn:

  • Why adaptive milling strategies fail in production (and how to predict it)
  • How to validate turn-key tooling solutions before customer trials
  • Controller-specific feedrate behavior in high-speed applications
  • AMRC Case studies

Real-World Applications:

  • Aerostructure components (ribs, spars, panels)
  • Thin-wall aluminum and titanium parts
  • High-removal roughing strategies
  • Precision finishing on complex geometries

45-minute presentation + live demo + 10-minute Q&A

If you have any questions about this webinar or the series, please email info@digitalcnc.ai.

Hosted by CEO Dr Rob Ward

Expert Insight from our Guest Speakers

Aerostructures and Landing Gear Team, The Machining Group, AMRC

Ryan Fletcher – Innovation Fellow
AMRC

Joseph Berner – Senior Project Engineer
AMRC

Webinar Three | Thursday 9th April 15:00 GMT

What Your CAM Software Doesn’t Tell You About 5-Axis Machining

Feedrate fluctuations in simultaneous 5-axis create witness marks and surface defects – but CAM can’t show you where they’ll occur. The result? Surface artifacts you don’t discover until the part comes off the machine.

The problem isn’t your CAM system or your machine.

It’s the invisible gap between what CAM assumes and what your machine can actually deliver. Learn how to bridge the gap between CAM and CNC for 5-axis work – using machine-specific kinematic data to predict and prevent quality issues.

What You’ll Learn:

  • Why feedrate variations in 5-axis show up as finish defects
  • Why 3+2 is often faster than 5-axis
  • Why vector programming needs machine-specific validation
  • Identifying slowdown zones that create witness marks—before cutting metal

  • Testing strategies offline to negate finish defects caused by feedrate fluctuations

Real case study: 5-axis aerofoil case study – pinpointing exact slowdown zones and surface defects—in hours instead of days on the machine.

    Who Should Attend:

    • CNC Programmers laying down 5-axis toolpaths

    • Production managers tired of surprised cycle times
    • Quality Engineers investigating surface defects
    • Anyone transitioning from 3-axis to 5-axis machining

    35-minute presentation +10-minute Q&A – including demo and case studies

    If you have any questions about this webinar or the series, please email info@digitalcnc.ai.

    Hosted by CEO Dr Rob Ward

    Expert Insight from our Guest Speakers

    Webinar Four | Thursday 7th May 15:00 GMT

    Building the Business Case

    “Building the Business Case – ROI & Implementation of Virtual Machining”

    Perfect For:

    • Engineering managers justifying virtual validation investment
    • Production directors seeking capacity gains without new machines
    • Solution provider leadership evaluating competitive differentiation
    • Operations leaders responsible for NPI and process development

    What You’ll Learn:

    • Quantifying the true cost of trial-and-error (direct + indirect + opportunity costs)
    • ROI models: £ capacity gains + £ trial elimination examples
    • Integration with existing CAM, verification, and shop floor workflows
    • Change management: Getting buy-in from programmers and customers

    45-minute presentation + live demo + 10-minute Q&A

    If you have any questions about this webinar or the series, please email info@digitalcnc.ai.

    Hosted by CEO Dr Rob Ward