stonemasonry

CONTENTSProduct overview

Alphastone Standard

Alphastone Advanced

Alphastone 2D Engrave

Alphastone 3D 3-Axis

Alphastone 5-Axis

Case Study

PRODUCT OVERVIEWAlphacam is one of the leading and most established suppliers of CAD/CAM soft-ware for the stone industry. The Alphastone modules have been specifically devel-oped to address the unique challenges encountered when machining marble andstone. Any configuration of machine, from simple 2-axis to complex 5-axis, is sup-ported, as well as all the specific cutter types used within the industry.

We work with a wide range of companies, from smallniche stonemasonry companies which manufacturebespoke and intricate products, to larger volume players.

Part of the Planit group offering world classsoftware for the stone, woodworking, cabinetmaking and engineering industries, our sys-tems are best-in-class within our respectivemarkets and are integral to the success ofmany companies around the globe.

Naturally, Alphacam iscompatible with all CNCmachines, production con-trol software and Microsoftsupported Windows plat-forms, including WindowsXPTM.

One of our most high profile customers is Gaudi’s stun-ning Sagrada Familia in Barcelona. Attracting over 2 mil-lion visitors each year, the cathedral is revered by theWorld of Architecture as one of the most original andambitious modern buildings. Alphacam is being used toprogram CNC machines to cut the intricate stone com-ponents more accurately and significantly more quicklythan could ever be achieved by traditional methods.

ALPHASTONE STANDARD

ALPHASTONE ADVANCED

2.5D and 3D profiles can be quickly and efficiently roughedusing disk cutters, taking into account any stock material.This is particularly useful when roughing wash basin andbath tub shaped features.

Disk cutters can be used in any orientation to finishsculptured 3 dimensional surfaces.

The Marble module has the ability to import bitmapformat art work and convert these images into 3dimensional machining moves. STL files can also beimported and machined, making links to 3 dimen-sional laser scanners easy. There is full core drillsupport for both 2 and 3 dimensional materialremoval and depths of cut are automatically detect-ed as well as tool depth limitations.

ALPHASTONE 2D ENGRAVE

ALPHASTONE 3D 3-AXIS

ALPHASTONE 5-AXIS

Alphastone gives the user the ability to define any type of cuttingtool, from disk cutters with programmable guards to ball end anduser defined form tools. Alphacam automatically calculates the pro-gramming point of each tool from the material contact point.

Alphastone has the ability to import bitmap format artwork and convert theseimages into 3D machining moves. STL files can also be imported and machined,making links to 3D laser scanners easy.

There is full core drill support for both 2D and 3D material removal and depths ofcut are automatically detected as well as tool depth limitations.

Multiple 5-Axis machining strategies, with full tool gouge detection, makes com-plex machining simple. These strategies can be saved as machining styles andthen combined to easily build multiple tool rough/finish operations.

CASE STUDYThe world-famous Sagrada Familia in Barcelona is renowned for its stunning architec-ture, based on complex and innovative geometrical shapes. Started in 1882, the projectis still estimated to be at least 80 years from completion. However, Alphacam is playinga major role in streamlining the production of components from locally quarried stone,not just to ensure that they are available on time, but also fit together ‘right first time’.

Much of the temple’s top level design is undertaken to Gaudí’s specifica-tions in CATIA. This is imported directly into Alphacam, where it is con-verted into fully specified NC code for the machining centre.When the proportions of the finished model exceed the z-axis capabilitiesof the machine, Alphacam sub-divides the design data into layers, thenautomatically generates the NC programmes to produce a set of laminat-ed components for final assembly.

The use of Alphacam software by the SagradaFamilia Foundation closely mirrors the prin-ciples employed by Antonio Gaudí from hisearliest days in charge of the Temple’s con-struction. Installed in 2004, along with amulti-axis machining centre, theCAM software is employed to produce accu-rate models - typically at 1/10 scale - inengineering foam and plastics, before com-mitting to full size production in stone.

“This is very much the way Gaudíworked a century ago, making minia-ture versions of all types of architec-tural details to determine how com-plex intersections in the geometrycould be produced successfully,” saysIgnacio Lumbreras, head ofAlphacam’s operations in Spain.

“It’s strange to talk about what areeffectively rapid prototyping tech-niques in the context of a project thatis still nowhere near finished after 123years. But that is exactly how ourprogramming software is used.”

“The system’s powerful programmingcapabilities are backed by ease ofuse,” says Lumbreras. “This is whereAlphacam really scores over mosthigh end systems. Furthermore, withpost-processors available for all majorstone-working machines

Alphacam israpidly establishing itself as the sys-tem of choice for many stone cuttingcompanies in Spain.”

Previously, all the scale models constructed in the Sagrada Familia’s workshops were producedmanually. This approach was not only labour and skills-intensive, but also open to interpreta-tional and human errors. Now the project engineers can employ advanced, on-screen visualisa-tion checks and clash detection routines to fully prove out every component’s design and manu-facturing method - from the structure’s massive support pillars and windows, to intricate roofjoints. In addition, Alphacam is employed to produce templates, jigs and fixtures used through-out the temple’s on-site laboratory and model making areas.

Once design and manufacturing details havebeen confirmed, the Sagrada FamiliaFoundation has the option of producing fin-ished components in house, or supplyingCATIA and/or Alphacam files for thestonework to be outsourced from a panel ofup to 15 sub-contractors.

With the speed and accuracy derived fromAlphacam, the prospect of finally completingGaudi’s incredible dream is now a reality.