The development and manufacture of cryogenic test apparatus is a highly specialized field with a very niche market: a market that includes a deadly serious application. Specifically, cryogenic test dewars allow infrared sensors and arrays to be tested within an enclosed environment that supports very cold temperatures. These infrared technologies can include night-vision products and infrared astronomy imagers, as well as sensors for defense applications like heat-seeking missiles and early detection and warning satellites. Development and production of these sensors requires quality test apparatus, such as dewars, which enable testing at ultra-low temperatures.

Triad Solutions LLC develops test dewars for Infrared Focal Plane Arrays (IRFPA) and IR discrete devices. As a small but growing company with five employees, the operation relies on a combination of design and manufacturing quality with the ability to keep overhead as low as possible. The company uses TurboCADCAM, an affordable yet functional computer-aided design product that allows for direct-to-NC programming from 3D designs. (Shown here, major assemblies of a cryogenic test dewar.)

Based on TurboCAD v10, the TurboCADCAM application allows 3D models to be read directly to G-code (the language that communicates with NC machines), from which machining can be commenced. With the release of v10, TurboCAD integrated highly sophisticated CAD format translators that enable the import and export of 3D CAD data without a hitch. This means that many manufacturing companies can easily use 3D designs, delivered by a client, directly in machining and cutting processes.

Triad Solutions implemented TurboCADCAM early in 2004 along with a desktop CNC machine by MicroProto Systems. Using this system, the company can manufacture low-volume parts in-house for its test dewars.

"We knew that our customers wanted suppliers that use CAD data and who can optimize it," said Jeff Smith, Triad Solutions president. "While we looked at several higher priced CAD systems, we found that TurboCAD offered us everything we needed -- and more -- at a fraction of the price." (Illustrated, cryogenic test dewar with cold shield and vacuum cover removed.)

Using TurboCADCAM, the company designs test apparatus and parts in 2D and 3D, and also provides realistic 3D renderings of designs for customers that need to see a new design. Client design data are also imported into the software using the advanced IGES and STEP translators that were fully integrated with TurboCAD on its latest release. The software also reads DWG and DXF file formats as well as many others.

"Translating the data has been very straightforward in TurboCAD," stated Smith. "We are able to swap data with very little loss of information via this system."

Easy Implementation

Triad was relieved to find that implementing the system was easier than they had expected, requiring a few weeks of testing and setting up the system and ensuring quality. In fact, Triad found itself making quality parts within a couple of weeks of implementing the system.

"I was not very experienced in mechanical CAD, but found that the system was easily put to use with quick studies of the user guides," said Smith. "We have all found it an enjoyable system to use and learn." He added, "Also very useful has been the expert technical assistance available with just a simple phone call. I have never been able to 'stump' the experts with my questions or problems." (Shown here, cryogenic test dewar.)

During the design and manufacturing process, Triad staff decides whether to create parts in-house or to outsource them. Low-volume and prototype parts have proved especially easy to create in-house, with TurboCAD able to create machine code directly from the 3D model.

"Creation of the G-code (the machining language to run the CNC system) is automated in TurboCADCAM," said Smith. "Although getting precisely the right settings is a focused job, it has proved worthwhile in being able to machine highly accurate parts directly in the shop. We love it!"

Designs that will be manufactured elsewhere are supported by the 3D design data created in TurboCAD, which can be exported rapidly and emailed or sent on CD.

The Results

"Our customers totally value our ability to create, use, and leverage 3D data," said Smith. "This has put us ahead of various competitors in terms of service, turnaround time, and quality of product."

The company invested a total of $2,500 in the entire system and software. They also estimate that the investment was paid for within 4 months through increased market share and improved productivity.

"The ROI is part of our satisfaction, but the support and contact with IMSI (developers of the software) has impressed us," said Smith. "The day that the new version of TurboCADCAM was released, the company called us to check that we wanted the upgrade. That is the kind of attention that helps out users in the real world."