TV Chopper Artists Carving With Mastercam

The Challenge

OCC is trying to ramp up production to the point where it can produce a small line up of limited edition bikes and boost overall production to 120 bikes in 2006 and as many as 200 in 2007 (they do 80 currently). OCC needed to streamline their production manufacturing procedures to achieve these output targets.

Mastercam X Mill, Wire, Solids, and Nesting

• OCC uses Mastercam to seamlessly translate part designs created using CAD software into toolpath programs that drive CNC equipment accurately and efficiently.
• Mastercam plays a pivotal role in the company’s plans to expand operations to make its wares available to a somewhat broader market.
• OCC imports designs from SolidWorks, IGES, or other CAD files into Mastercam and translates them into programs.
  Mastercam’s Design capability lets OCC design unique parts within Mastercam – without having to use any other programs.
• OCC uses Mastercam to refine or redesign tooling and fixtures for increased productivity.
  With Mastercam, OCC’s “parts can be cut at higher speeds with less tooling force for a faster production cycle and better surface finish.”
• Mastercam’s 3D surfacing toolpath “is wonderful.” The polishing they do to get parts ready for chroming is very minimal.

The American Chopper TV show lets viewers look over the shoulders of the designers and machinists at Orange County Choppers (OCC) as they conceive and build one-of-a-kind chopper motorcycles and accessories.

OCC is very high tech. They rely on the latest waterjet system capable of cutting through ceramic, glass, even a 12-inch block of steel with minimal heat and no distortion of the material. They use a mandrel tube bender to create unique snaking exhaust systems without leaving any ripples in the metal. Advanced CNC lathes and mills turn and cut these exotic and beautiful parts.

OCC imports its designs seamlessly from SolidWorks, IGES, or other CAD files into Mastercam and translates them into manufacturing programs. Mastercam itself has substantial design capabilities and OCC also creates unique parts within the Mastercam graphic environment.

Semi-Production Bikes
In 2006 OCC began expanding its manufacturing capacity. The first step was moving its bike manufacturing operations into a new 100,000 sq. ft. facility where it can produce selected bikes on a semi-production basis. Lead Engineer, Jim Quinn said that OCC will have to streamline its manufacturing procedures to achieve output targets.
Jim and his staff will be using Mastercam to refine or redesign tooling and fixtures for increased productivity. For example, an adjustable jig designed in Mastercam and used to fabricate custom bikes will be redesigned for production of limited-edition vehicles. The custom jig makes it possible to adjust the bike’s “rise” and “stretch” to make each bike’s dimensions proportional to the measurements of the person who will be riding it most often. It’s a great timesaver in building custom bikes.

“Once we are ready to make hundreds of bikes with the same ‘rake and ride’ specifications, we already have that jig designed in Mastercam,” said Quinn. “It will be quite easy to go back in and duplicate the dimensions we need, take out a lot of the adjustability, and generate the CNC programs to make our production jig.” The same concept also holds for other tooling and fixtures.

Production Ready Accessories
The old plant will become the CNC production shop. OCC intends to “cherry-pick” its custom part, accessory, and wheel designs to identify ones that would be most appealing to fans and manufacture these on a production basis. “Nasty Wheel,” the engraved Orange County Chopper logo air cleaner cover and the OCC Dagger Shield coil cover will be among the first.

Mastercam will have a central role in optimizing part manufacturing productivity. The OCC Dagger Shield coil cover, the company’s signature accessory, is a prime example. It was designed in SolidWorks and imported into Mastercam. Quinn said, “Mastercam allows me to turn, manipulate, and move that part into whatever situation I need to hold it securely and machine it efficiently. Because the work piece is already cut to near net shape with only light cuts required around the perimeter of the shield, the part can be cut at higher speed with less tooling force for a faster production cycle and better surface finish.”

Quinn said that the first couple times this part was made on a prototype basis; the complete process took about six hours. Now after tweaking the various steps, they have the time down to one and a half hours. The part is production-ready.

Loyal Fans Rewarded
In just six years Discovery Channel viewers have watched OCC grow from three employees to 60, and boost its production to 80 commissioned custom choppers in 2005. The new plant will allow OCC to boost overall production to 120 bikes in 2006 and as many as 240 in 2007.

That’s not all. Quinn said, “We want to let our fans participate in some of that OCC flair without buying a $65,000 OCC chopper. They already have OCC on their backs with our T-shirts. As production of our signature parts ramps up, they’ll also be able to have OCC on their bikes.”

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