Mastercam Mill
Mastercam Mill is CAM software designed for programming CNC milling machines, covering everything from programming basic parts to demanding multi-surface 3D machining. The Mastercam Mill product family is available in three license levels: Mill Entry, Mill, and Mill 3D. The appropriate license level is selected based on the parts to be manufactured, the machine tools used, and the required machining methods.
Mastercam Mill is suitable for vertical- and horizontal-spindle machining centers, bed-type milling machines, gantry milling machines, and various multi-axis machining centers. Mastercam provides a single software environment for everything from simple prismatic parts to demanding multi-surface and multi-axis machining.
Mastercam Mill for CAM Programming of Milling Operations
In Mastercam Mill, toolpaths are created directly from 2D or 3D CAD geometry. Mastercam Design’s CAD features are included in all Mill product family license levels, so geometry can be created, repaired, and modified within the same Mastercam environment used for CAM programming. Current Mastercam Mill solutions also include tools for editing and preparing imported models before machining.
Toolpaths are associative, so when the geometry or machining parameters change, the toolpath can be recalculated without rebuilding the entire program from scratch. Previously created operations can also be copied and reused in new jobs, speeding up the programming of similar parts and recurring machining processes.
Mastercam Mill is suitable for programming both individual parts and production runs. In addition to toolpaths, programming can include managing tools and the machine environment and, depending on the license level, the stock model and machine simulation.
Mastercam Mill Entry, Mill, and Mill 3D for Different Milling Needs
The three license levels in the Mastercam Mill product family differ primarily in the scope of their CAM capabilities. Mill Entry is suitable for programming basic parts, Mill is a comprehensive general-purpose license for machining conventional machine-shop parts, and Mill 3D expands the package to full-scale multi-surface 3D machining.
Mastercam Mill Entry is suitable for parts that can be machined using standard 2D and 2.5D milling and drilling methods. Typical features include flat surfaces, profiles, pockets, slots, and holes.
Mill Entry includes the essential tools for CAM programming of these types of parts, as well as for managing CAD geometry, tools, and the machine environment. It provides an effective solution for programming basic parts, but does not include the more advanced features of the Mill license, such as 2D Dynamic Motion toolpaths, stock models, machine simulation, or more extensive 3D machining capabilities.
Mill Entry is therefore a suitable choice when the parts being machined are relatively simple and production does not require advanced roughing, simulation, or 3D capabilities.
Mastercam Mill is the product family’s comprehensive general-purpose license for conventional machine-shop production. It is suitable for parts that combine features such as flat surfaces, external and internal profiles, pockets, slots, shoulders, holes, threads, chamfers, and individual contoured 3D surfaces.
The Mill license provides more advanced machining capabilities than Mill Entry, including 2D Dynamic Motion toolpaths, stock models, feature-based operations, advanced hole-making methods, machine simulation, and the ability to perform 3+2-axis machining.
Mastercam Mill also includes 3D machining capabilities. 3D toolpaths can be used on individual surfaces, while OptiRough, based on Dynamic Motion technology, can also be used for multi-surface 3D roughing. OptiRough has been available at all Mill product levels, and Mastercam continues to use it as part of its current material-aware roughing methods.
In practice, Mill is the appropriate license level for a large portion of conventional machine-shop production where, in addition to 2D and 2.5D machining, efficient roughing, stock awareness, simulation, or machining of individual 3D features is required.
Learn more about Mastercam Mill 2D toolpaths
Mastercam Mill 3D includes the capabilities of the Mill license and expands the package to full-scale multi-surface 3D machining. It is intended for parts whose machinable geometry consists of multiple interconnected 3D surfaces or complex solid geometry.
Typical applications include molds, tooling, and other parts containing demanding freeform surfaces. Mill 3D provides comprehensive methods for roughing, rest machining, semi-finishing, and finishing multi-surface and solid-based geometry.
The difference compared with the standard Mill license becomes especially apparent when entire multi-surface shapes are machined instead of individual 3D surfaces, and the toolpaths must handle large, continuously changing 3D geometries.
Dynamic Motion and OptiRoughing for Efficient Material Removal
Mastercam’s Dynamic Motion is a material-aware toolpath technology that adapts tool movement based on the actual condition of the stock. The technology aims to keep tool engagement and chip load under control instead of requiring cutting parameters to be sized for the worst-case load anywhere along the toolpath.
Dynamic milling typically uses a small radial depth of cut, ae, and a large axial depth of cut, ap. This allows more efficient use of the tool’s cutting length and distributes wear across a larger portion of the cutting edge. Controlled tool engagement and smooth movements also enable higher feed rates and high material removal rates.
According to Mastercam, Dynamic Motion can reduce machining times for actual roughing and pocketing operations by 25–75%. The manufacturer also reports that tool life has improved by as much as 3–5 times in some applications, as controlled chip loads reduce heat, vibration, and uneven tool wear.
The benefit does not come solely from faster tool movement. Dynamic Motion reduces unnecessary air cutting, prevents the tool from plunging too deeply into the material, and adapts tool movement in areas such as corners and pockets. The goal is a higher material removal rate, shorter machining times, and more predictable tool loading.
OptiRough, which is based on Dynamic Motion technology, brings the same material-aware approach to 3D roughing. The toolpath takes the stock and remaining material into account and focuses machining on areas where material still needs to be removed. Mastercam continues to position Dynamic OptiRough as one of the key advanced machining methods in its Mill solutions.
Stock modeling and simulation as part of programming
With Mastercam Mill and Mill 3D licenses, the stock model can be used to track material removal between operations. Subsequent operations can use this information to identify remaining material and target machining to the areas that require it. This makes it easier to manage leftover material and helps reduce unnecessary tool movements.
Toolpaths can be reviewed before generating NC code and running the machine. Machine simulation, included with Mill and Mill 3D licenses, allows programming to be reviewed in a modeled machine environment and potential issues to be identified during the programming stage.
Reviewing the stock, toolpaths, and machine environment in the same software helps evaluate not only individual operations but the manufacturing process for the entire part.
Expanding Mastercam Mill License Milling Capabilities with Add-Ons
The Mastercam Mill environment can be expanded with separate add-ons when production requires machining, measurement, or specialized capabilities beyond the standard features of the license level.
Mastercam Probing brings machine tool measurement and probing capabilities to CAM programming. Measurement programs can be used, for example, to position a workpiece, define the work coordinate system, and perform in-process inspection.
Mastercam Multiaxis extends milling to continuous 4- and 5-axis machining. It is suited for parts where the tool orientation must be continuously controlled throughout the toolpath due to complex geometries, accessibility requirements, or machining conditions.
Mastercam Blade Expert is a specialized solution for multiaxis programming of blades, vanes, and similar geometries. It includes functions designed specifically for these types of parts, helping automate and accelerate the programming of demanding blade geometries.
Mastercam Port Expert is intended for the multiaxis machining of engine intake and exhaust ports, as well as other tubular channels. Its toolpaths are specifically designed for programming deep and difficult-to-access channel geometries.
Mastercam Mill scales with your production and machine fleet.
The Mastercam Mill product family lets you tailor your CAM solution to your current production needs and expand it later as the parts being manufactured, machine fleet, or machining methods change. Programming can begin with standard 2D and 2.5D milling, then progress to more demanding 3D and multiaxis machining within the same Mastercam environment.
You can upgrade from a Mill Entry license to a Mill or Mill 3D license, and supplement the solution with add-ons for applications such as continuous 4- and 5-axis machining, machine tool probing, and programming complex specialized geometries. This means that acquiring a new machine tool, introducing more complex parts into production, or adopting new manufacturing methods does not necessarily require switching CAM systems; instead, your existing Mastercam environment can evolve alongside your production needs.
Contact our Mastercam experts to learn more about Mastercam Mill solutions.
