Intuitive systems are crucial for CAD/CAM training of workers

Editor's Note: This article originally appeared in the October 2025 print edition of Today's Medical Developments under the headline “Intuitive CAD/CAM crucial for training workers”.

A 2023 analysis by Vantage Market Research predicted the medical laboratory automation industry will reach almost $9 billion by 2030. Factors contributing to this growth include advancements in laboratory robotics, the rise in demand for personalized medicine, and growing investment in healthcare infrastructure. As the number of lab tests rises globally, so do their standards and funding, creating a perfect storm for manufacturers specializing in automated lab equipment. Meeting that demand is challenging since high-tech medical laboratories require precise machinery and the current skills gap has left many manufacturers searching for workers.

Scinomix manufactures machines for large medical research labs across the globe. These machines are designed to automate repetitive lab tasks such as labeling sample tubes, microplates, and precision aliquoting. Their family of automation systems provide solutions for bulk tube feeding, tracking, and capping. The company produces more than a hundred machines per year, with most of their components being machined in-house and programmed with Tolland, Connecticut-based CNC Software’s Mastercam provided by Weldon Spring, Missouri-based certified resellerQTE Manufacturing Solutions.

“Versatility and equipment footprint are some of our major selling points,” says Machine Shop Lead Jonathan Gancheff. Each machine is considered a benchtop unit and is designed to accommodate the specific needs of each laboratory environment. Since the medical lab automation industry is dominated by large, cumbersome equipment, customers appreciate when solutions come in tiny boxes.

When Scinomix does manufacture a larger assemblage, it’s usually a combination of multiple machines. For example, its AQ Aliquoting System is a fully automated vial handler that pairs with other products to load, label, fill, recap, and remove vials sterilely, quickly, and accurately. Maintaining chains of custody and process records are of utmost importance when human health is involved, so each system runs on Scinomix software that ensures comprehensive mapping of source-to-destination runs.

From design to finished product

Scinomix employs specialists in a variety of fields, six of whom work in the machine shop. The shop runs primarily on CNC milling which doubled in capacity during COVID-19. The company now has four Haas VF4s supported by a full range of manual machining equipment. Though used less frequently, a MultiCam Apex1R CNC router was added a year ago and is expected to improve workflow. Gancheff explains that most parts are currently being machined in three axes, although the machining team has its collective eye on multi-axis machining.

Gancheff manages everything that comes through the shop, from design to following the product out the door. Part of the reason he was hired a decade ago was because of his experience with Mastercam. Scinomix had recently switched from another software, mainly due to the design iteration process. “They wanted to take a design, make a modification to it, and have that program ready to machine as quickly as possible,” Gancheff recalls.

These days, Gancheff regularly puts the Mastercam software through its paces with complex parts for machines such as the Sci-Print MP2+. The Sci-Print is an automatic labeler for microplates and deep well blocks. This high-throughput machine can hold up to 48 plates and move them via a small conveyor system. Plates can be scanned via barcode before the rotating, height-adjusting platform allows the plate to be labeled anywhere on the block.

The base of the MP2+ begins as a 30 lb slab of 6061 aluminum and ends as a 5 lb frame. There are dozens of tapped holes, 40 reamed holes, and the rest is almost entirely pocketed out. Standard tolerances are ±0.003", although some geometries are ±0.0005".

Gancheff says the software’s dynamic toolpathing was the best approach for these complex cavities. Dynamic Motion technology directs tool engagement so excess heat is eliminated, keeping tools and stock safer. It also allows for feeds and speeds that would otherwise be impossible, especially around corners.

“Given the massive material removal and associated stresses of the part, Dynamic has made it possible to get consistent results,” he says of the cutting approach, which decreases cycle time 30% to 40%. “It’s a very reliable toolpath. It’s not jamming the tool into the corners; it’s keeping perfect engagement throughout the machining process.” Gancheff trusts the Dynamic approach to cut well and keep tools safe without someone babysitting the machine for hours.

3D OptiRough is an advanced roughing strategy within the Dynamic family. OptiRough uses a bi-directional cutting strategy directed by Dynamic’s advanced algorithms. It harnesses the traditional benefits of Dynamic, namely extended tool life and reduced cycle times. Even some of Scinomix’s less complicated 2D parts benefit. “I wouldn’t do any new programs without taking advantage of the Dynamic toolpaths,” Gancheff says.

For parts machined on the shop’s router, Gancheff relies on his software’s automated toolpath and geometry nesting. The customizable nesting feature arranges parts to maximize material use and eliminate waste.

When it comes time to apply one of the 348 tool types Scinomix keeps in inventory, any employee can make the best choice. Gancheff has curated a virtual catalog of all the tools within each machine and their associated feeds and speeds. “As long as someone programming the part knows what material they’re using, they don’t have to worry about setting most parameters. They just go in and select their tool and run,” he says.

Before the part goes to production, though, it must run through the software’s Verify function. Verify is a simulation tool that confirms stock removal metrics and checks for possible collisions with workholding fixtures and stock.

“We use it to compare the solid model features to what the NCI data is reporting will be produced to make sure it matches,” Gancheff says. The few extra minutes ensure a flawless machining cycle, even for inexperienced programmers.

Automated solutions for ease of use

The Tool Library and Verify features add to Gancheff’s ability to offload tasks to his team. “In our experience, we’ve had a hard time finding experts in any CAD/CAM program,” he says. “But this makes the process easy to explain.” He has had an employee in the shop for less than one year who is already comfortable making program changes, adjusting feeds and speeds, and troubleshooting common issues.

Originally, Gacheff’s training process meant having to learn every detail. He felt pressure to have his team memorize parameters and tools. When he began taking advantage of the automated solutions within his CAD/CAM system, he realized there was no need for memorization. He then began teaching his team how best to apply the software’s functions.

“I immediately saw results,” he says. “Now I’m not certain it was reasonable to have everybody doing things the hard way just for the sake of the learning process.” Gancheff keeps updated sets of operation defaults on each machine so his programmers and machinists can focus on the truly important tasks in the shop.

Occasionally there’s a call for more advanced software applications for more complicated machine assemblages. In these cases, Gancheff is happy to send his team to train with reseller QTE. QTE’s training courses are held virtually or in certain cities to reduce the travel expenses of attendees. Gancheff has often sent individuals or groups to one of QTE’s locations to be trained by industry experts. Scinomix keeps a maintenance contract with its reseller so employees can call or email QTE experts anytime to help solve problems.

As the laboratory automation sector continues to grow at a rapid pace, so will Scinomix. Innovation is a key component of the company culture, and its team always has new product developments in the works. This is a large part of the reason Scinomix is becoming a household name in laboratories across the globe.

Mastercam
https://www.mastercam.com

QTE Manufacturing Solutions
https://qtemfg.com

Scinomix
https://scinomix.com