COMAT Relies on hyperMILL® for Maximum Precision in Space Manufacturing: A Strong Partner for the European Space Industry
COMAT | Flourens, France
Key Takeaway
As a strategic supplier to the aerospace industry, French company COMAT uses hyperMILL to manufacture high-precision components for satellites and scientific missions. The CAM solution impresses with its advanced 5-axis and simulation technology that ensures greater process reliability and efficiency, delivering decisive advantages for complex applications in the demanding space sector.
Since its founding in 1977 in Flourens near Toulouse, COMAT has established itself as a strategic partner of the space industry. In its early years, COMAT specialized in instruments for microgravity applications such as the MIR, FOTON, and ISS space stations. It quickly became a European market leader in this field.
With its integration into the AGORA Industries Group in 2008, a new chapter began for COMAT. This evolution marked growth, technological advancement, and new market opportunities. The company’s goal was to become a leading supplier of space equipment in Europe.
To meet the growing demands of its customers, COMAT continuously invests in expanding its manufacturing capacities, focusing on innovation, reliability, and efficiency. A key component of this strategy is the company’s in-house 'Design-to-MAIT' concept (Manufacture, Assembly, Integration, and Test). To fully leverage the potential of its state-of-the-art machining centers, COMAT now relies on the powerful CAM solution hyperMILL® from OPEN MIND.
Within four years, COMAT developed and manufactured more than 2,000 parts for the five prototypes and the flight model of the SuperCam. The company’s engineers worked closely with the teams from IRAP and CNES to install the instrument in a cleanroom environment.
“For programming and machining very complex components, hyperMILL® is the best CAM solution there is.”
Alexis Lannay, Head of Production, COMAT
Extreme Conditions Require Maximum Precision
Manufacturing for the space industry demands extraordinary levels of precision and reliability. As Alexis Lannay, Head of Production at COMAT, explains, maintenance work in this field is highly complex. Therefore, all systems must function flawlessly over long periods of time.
High-quality materials such as aluminum-silicon alloys are used. They must withstand extreme temperature fluctuations yet are very brittle and difficult to machine. To prevent cracking, surface roughness of Ra1.6µm and tolerances of only 5µm are required, an enormous challenge for any manufacturing process.
Expertise in Space, Science, and Industry: With its know-how in aerospace, science, and industrial manufacturing, COMAT develops innovative technologies precisely tailored to customer needs.
From One-Off Parts to Series Production
Until 2019, COMAT mainly produced structural and precision parts for observation satellites for applications such as weather and sea-level measurements. The size of these components range up to 500mm3 and were usually produced as single parts with long machining times and low production rates, similar to prototyping.
With its entry into the nano satellite market for communication systems (TV, Internet, etc.), the company’s production changed fundamentally. These satellites operate in constellations. So, if one unit fails, another takes over its function. As a result, production series became larger with production runs from 50 to 200 units, and the parts also became significantly more complex. The CAM software previously in use quickly reached its limits, leading COMAT to opt for a change in technology.
hyperMILL® Proves Itself in Practice
To find the best solution, COMAT conducted a benchmark in which three leading CAM systems were tested using highly complex aerospace components. Evaluation criteria included performance, user-friendliness, flexibility, and implementation effort. The result was clear: hyperMILL® impressed above all with its performance in complex 5-axis simultaneous machining. The clearly structured and practice-oriented implementation process also convinced the COMAT team.
Faster, Safer, More Efficient – hyperMILL® in Use
COMAT implemented hyperMILL® in March 2020. Shortly afterwards, the company received a short-notice order from Airbus to manufacture two particularly demanding components. “The challenge lay not only in the parts themselves but also in the extremely tight delivery deadlines,” recalls Alexis Lannay. “Thanks to the support of the hyperMILL® experts from OPEN MIND, we were able to complete the machining safely and on time.”
Easy to use interface, even for Complex Parts: The hyperMILL® user interface remains clear and intuitive — even when programming the most complex geometries.
Significant time savings, in complete safety, with the use of hyperMILL®
Today, the production team led by Alexis Lannay programs daily with hyperMILL®. A total of seven machines — from 3- to 5-axis machining centers are now in operation. According to Lannay, the hyperMILL® MAXX&nbsü;Machining roughing module has proven to be a major step forward: “We’ve reduced machining times by about 25%. Unnecessary movements are avoided, making the processes more efficient and easier on the machines.”
To further increase efficiency, COMAT has developed its own tool database in hyperMILL®, which is regularly updated. It contains tools and corresponding strategies organized by material groups, including speeds and feeds. This structure allows proven processes to be reused efficiently and contributes significantly to increased productivity.
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Automated Workflows and Safe Processes
Lannay also appreciates the NC code-based simulation technology hyperMILL® VIRTUAL Machining: “This solution reproduces real machine kinematics, allowing possible collisions to be detected and avoided before machining to ensure absolute safety.” With the Optimizer module, all toolpaths are automatically optimized; unnecessary movements are eliminated, keeping the process stable and reliable.
During calculation programming can continue and this saves valuable time. The production manager summarizes: “The success formula for manufacturing highly complex and reliable aerospace parts lies in the combination of an innovative software solution and an experienced team of CAM programmers. In addition, the developments from OPEN MIND for the CAM software are top-notch; we’re delighted.”
Simulation of tool paths with the Optimizer module (left) and without (right)
Optimized Transitions with the Optimizer Module: Using the Optimizer module, hyperMILL® automatically calculates smooth transitions between machining steps.
First-Class Service from a First-Class Team
COMAT also values the reliable and responsive support provided by OPEN MIND, which helps the company continuously advance its CAM programming. Alexis Lannay maintains regular contact with OPEN MIND’s experts, enabling COMAT to make effective use of automation technologies. The next step is the upcoming integration of a 5-axis mill-turn center. Here too, COMAT relies on the hyperMILL® TURNING Solutions for turning and milling.
Safe and reliable: hyperMILL® VIRTUAL Machining enables realistic, safe simulation and optimization of even the most demanding operations.
