Software aids rock-solid production

Edited by the Engineeringtalk editorial team Jan 10, 2006

Alphacam software helps streamline production of stone components, not just to ensure that they are available on time, but also that they fit together "right first time".

The world-famous Sagrada Familia in Barcelona is renowned for its stunning architecture, based on complex and innovative geometrical shapes.

Started in 1882, the project is still estimated to be at least 80 years from completion.

However, Alphacam software from Planit is playing a 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".

The use of Alphacam software by the Sagrada Familia Foundation closely mirrors the principles employed by Antonio Gaudi from his earliest days in charge of the Temple's construction.

Installed in 2004, along with a multi-axis Bermaq machining centre, the CAM software is employed to produce accurate models - typically at 1/10 scale - in engineering foam and plastics, before committing to full size production in stone.

"This is very much the way Gaudi worked a century ago, making miniature versions of all types of architectural details to determine how complex intersections in the geometry could be produced successfully", says Ignacio Lumbreras, head of Alphacam's operations in Spain.

"It's strange to talk about what are effectively rapid prototyping techniques in the context of a project that is still nowhere near finished after 123 years".

"But that is exactly how our programming software is used".

Much of the temple's top level design is undertaken to Gaudi's specifications in Catia.

This is imported directly into Alphacam, where it is converted into fully specified NC code for the Bermaq machining centre.

When the proportions of the finished model exceed the z-axis capabilities of the machine, Alphacam subdivides the design data into layers, then automatically generates the NC programs to produce a set of laminated components for final assembly.

"The system's powerful programming capabilities are backed by ease of use", says Lumbreras.

"This is where Alphacam really scores over most high end systems".

"Furthermore, with post-processors available for all major stone-working machines, including IMT, Breton and Omag, Alphacam is rapidly establishing itself as the system of choice for many stone cutting companies in Spain".

Previously, all the scale models constructed in the Sagrada Familia's workshops were produced manually.

This approach was not only labour and skills-intensive, but also open to interpretational and human errors.

Now the project engineers can employ advanced, on-screen visualisation checks and clash detection routines to fully prove out every component's design and manufacturing method - from the structure's massive support pillars and windows, to intricate roof joints.

In addition, Alphacam is employed to produce templates, jigs and fixtures used throughout the temple's on-site laboratory and model making areas.

Once design and manufacturing details have been confirmed, the Sagrada Familia Foundation has the option of producing finished components in house, or supplying Catia and/or Alphacam files for the stonework to be outsourced from a panel of up to 15 subcontractors.

"Speed and accuracy are the key advantages delivered by the software", continues Lumbreras.

"It has been in use for more than a year now and the Foundation's engineers are gaining some major benefits".

"However, they also recognise that while Alphacam is easy to use, further training would help them move up a gear in terms of getting the best from their system".

"Once this additional training has been undertaken, maybe the temple's completion will come about all the sooner".