Advanced Computer Aided Manufacturing — Fusion 360 / Mastercam

Course Description

ETI2419C — Advanced Computer Aided Manufacturing — Fusion 360 (locally titled Computer Aided Manufacturing 2 at Pensacola State College) is a 4-credit, integrated lecture-and-laboratory course in the Engineering Technologies: Engineering Tech Industrial (ETI) taxonomy of Florida's Statewide Course Numbering System (SCNS). The SCNS state-level course detail describes the course as covering advanced concepts in CNC machines and CNC machining practices — including theory, operation, setup, safety, and practices. The course builds on the foundational CAD/CAM and CNC programming work introduced in ETI 2414C, with three principal areas of new content: 3- and 5-axis toolpath operations on solid models, tool and fixture design using CAD/CAM software, and proficiency on Mastercam as a second professional CAM platform (complementing the Fusion 360 base).

The course is offered in the Mechanical Design and Fabrication specialization of the Engineering Technology A.S. degree at Pensacola State College, where it is currently the only SCNS institution offering it. Pensacola State's Haas Technical Education Center (HTEC) shop facility — seven Haas CNC machining centers along with CNC plasma cutting and laser processing — supports the laboratory work. The "C" lab indicator denotes integrated lecture-and-laboratory delivery. Because this is a single-institution course, this guide reflects the Pensacola State implementation; instructors at other institutions adopting equivalent advanced CAM coursework should expect to adapt content for local software, equipment, and program-progression specifics.

ETI2419C is positioned as the fourth-semester capstone concluding the Engineering Technology A.S. degree in the Mechanical Design and Fabrication specialization. Per the course description, it serves both degree-seeking students preparing to enter employment and currently or previously employed CNC technicians seeking supplemental training. The capstone integrates the design, programming, setup, and machining skills developed across the program into a project portfolio executed on mill and lathe CNC machining centers. Course designation is AS-only; lab fees apply.

Learning Outcomes

Required Outcomes

Upon successful completion of this course, students will be able to:

Apply advanced 3-axis milling strategies, including high-efficiency adaptive clearing, rest machining, and combined rough/finish workflows on complex solid models.
Apply 4-axis indexed and continuous toolpath operations using rotary table or 4th-axis indexer configurations.
Apply 5-axis toolpath operations, distinguishing between 3+2 (positional / indexed) machining and full simultaneous 5-axis machining.
Design workholding fixtures using CAD/CAM software, applying the 3-2-1 location principle, datum selection, and clamp-and-locator placement appropriate to part geometry and machining forces.
Design cutting tooling and tool assemblies, selecting cutter geometry, tool holders, and tool stickout appropriate to feature, material, and machine.
Generate CAM programs in both Fusion 360 and Mastercam, demonstrating awareness of the conceptual mapping between platforms.
Use Mastercam Dynamic Motion toolpaths for high-efficiency roughing and finishing operations.
Apply advanced lathe operations, including profiling with multiple tools, threading, grooving, drilling on centerline, and parting.
Apply advanced CNC programming techniques, including subprograms (M98/M99), parametric programming with variables, and custom macros.
Perform advanced CNC mill setups, including multi-fixture (tombstone) configurations, soft-jaw operations, fixture plates, and probing-based setup.
Perform advanced CNC lathe setups, including soft-jaw turning, multi-tool turret configurations, and bar feed considerations.
Explain CNC machine theory, including closed-loop servo control, encoder feedback, ballscrew drive systems, axis configurations, and the role of the machine controller.
Apply advanced CNC safety practices, including emergency-stop architecture, machine guarding and door interlocks, light curtains, and procedures for setup, dry-run, and first-article validation.
Complete a capstone project portfolio integrating CAD design, CAM programming, fixture design, setup, and machined deliverables for multiple projects of progressive complexity.

Optional Outcomes

Depending on instructor emphasis, available equipment, and student goals, students may also:

Pursue Mastercam Certified Professional credentialing through Mastercam University online curriculum.
Apply in-process probing for setup automation, on-machine measurement, and tool-breakage detection.
Work with live tooling and C-axis lathe operations, including driven tooling for cross-drilling and milling on lathe-resident parts.
Modify or develop post-processors for specific machine configurations.
Apply coordinate measuring machine (CMM) measurement to verify finished-part conformance.
Apply design-for-manufacturability (DFM) principles to multi-axis-machined components.
Explore 5-axis kinematic configurations (trunnion / table-table, tilting head, head-head) and their effects on programming approach.

Major Topics

Required Topics

Advanced 3-Axis Strategies: Adaptive clearing for high-efficiency roughing; pocket vs. open-area approaches; rest machining workflows; semi-finish and finish strategies; surface-quality considerations.
4-Axis Machining: Indexed 4-axis (rotate-and-cut) using rotary tables; continuous 4-axis (rotary while cutting); 4th-axis fixturing; programming considerations for the rotary B or A axis.
5-Axis Machining — 3+2 (Positional): Defining tool orientation through rotary positioning; accessing undercut and complex faces; collision avoidance through tilt.
5-Axis Machining — Simultaneous: Multi-axis strategies including swarf cutting, parallel-to-curve, flow toolpath; tool axis control modes; stock and machine collision protection.
Mastercam Environment: Mastercam interface, workflow, and machine groups; setup; tool library; level/layer organization; chaining and geometry preparation.
Mastercam Mill Toolpaths: 2D toolpaths (contour, pocket, drill); 3D high-speed toolpaths; Dynamic Mill / Dynamic OptiRough; multi-axis toolpaths.
Mastercam Lathe Toolpaths: Rough, finish, groove, thread, drill cycles; canned cycles; sub-spindle and Y-axis operations where equipped.
Tool Design: Cutting tool geometry (rake, relief, helix); tool materials (HSS, solid carbide, indexable inserts); tool coatings (TiN, TiAlN, AlCrN, diamond-like); tool selection by material and feature; assembly modeling of tool-and-holder stacks for collision checking.
Fixture Design: Locating principles (3-2-1, planar / cylindrical / planar-pin); clamping strategies (toe clamps, swing clamps, hydraulic clamps); modular fixturing; soft-jaw preparation for lathe; tombstone and pallet-based setups.
Advanced CNC Programming: Subprogram structure (M98 / M99); local and global variables; conditional branching (IF / GOTO); custom macros (Haas G65); parametric programming for part families.
CNC Machine Theory: Closed-loop position control; resolver vs. encoder feedback; ballscrew vs. linear-motor drives; backlash compensation; axis kinematics; spindle motor types and orientation control; tool changer mechanisms.
Advanced Setup — Mill: Probing-based work coordinate setting (G65 macros, Renishaw cycles); soft-jaw machining for repeatable workholding; tombstone setup; multiple-WCS programming (G54–G59 and extended offsets).
Advanced Setup — Lathe: Soft-jaw boring for second-operation chucking; turret tool offsets and wear adjustments; multi-tool programming and turret indexing strategy; bar feed and part catcher considerations.
Advanced Safety: Emergency-stop circuit architecture; machine guarding standards; door-interlock function and override consequences; setup-mode vs. run-mode safety; safe approach speeds during dry run; first-article verification protocol.
Capstone Project Portfolio: Multi-project portfolio integrating model, fixture, CAM program, posted code, setup sheet, simulation captures, and finished-part inspection; presentation-quality documentation suitable for employment interviews.

Optional Topics

Post-Processor Customization: Reading and modifying post-processor files for specific machine and control configurations.
On-Machine Probing: Renishaw or Haas probing systems for work and tool measurement; probing macros; G31 skip-function basics.
Live Tooling and C-Axis: Driven-tool turret stations on lathes; C-axis positioning; cross-drilling and slotting on turned parts.
CMM Inspection: Probe calibration; feature measurement; GD&T verification; first-article inspection reports.
5-Axis Kinematic Configurations: Trunnion (table-table); tilting head; nutating head; head-head; their effects on reachable workspace and post-processor requirements.
Hybrid / Additive Awareness: Subtractive post-processing of additively manufactured parts; cleanup operations after 3D printing.
AS9100 Aerospace Quality Awareness: Documentation requirements and traceability practices relevant to aerospace machining work.

Resources & Tools

CAM Software — Primary: Mastercam (current version, education license) with Mastercam University online training portal; Autodesk Fusion 360 (continued use from ETI2414C)
CNC Equipment: Haas VF-series vertical machining centers; Haas ST-series and TL-series turning centers; 4th-axis indexers; full 5-axis machining capability where equipped (Haas UMC or comparable); CNC plasma cutting and laser processing
Training Resources: Mastercam University self-paced online curriculum; Haas Tip-of-the-Day video library; Renishaw probing training resources; Autodesk Design Academy
Reference Texts: Mastercam Reference Guide (current version); Tool and Manufacturing Engineers Handbook (SME); Fundamentals of Tool Design (SME); Machinery's Handbook; CNC Programming Handbook (Peter Smid); manufacturer documentation for cutting tools (Sandvik Coromant, Kennametal, Iscar, OSG, Haimer)
Tooling: Extended-reach end mills, ball-nose and bull-nose cutters, lollipop / undercut cutters, taper-shank holders, shrink-fit holders, lathe insert holders (turning, grooving, threading), specialty tooling for live-tool turrets
Workholding: Modular fixture plates, tombstones, dovetail vises, soft-jaw stock for mill and lathe, hydraulic clamps, fixture pins and bushings
Probing and Inspection: Tool-setting probes (laser or contact); workpiece probes; CMM (where available); surface plate; height gages; precision gage blocks
Standards and Codes: ASME Y14.5 (GD&T); ANSI/B5 machine tool standards; ISO 13041 (CNC turning) and ISO 230 (machine tool testing) for orientation; OSHA 29 CFR 1910 Subparts O (machinery) and S (electrical); AS9100 awareness for aerospace work
Professional Organizations: Society of Manufacturing Engineers (SME); National Tooling and Machining Association (NTMA); Precision Machined Products Association (PMPA)

Career Pathways

As the capstone of the Mechanical Design and Fabrication A.S. specialization, ETI2419C prepares students for direct entry into skilled CNC programming, setup, and operation roles, as well as advancement opportunities for currently employed technicians. The combination of CAD design, fixture and tool design, dual-platform CAM proficiency, and multi-axis machining experience positions graduates competitively for roles requiring both programming and shop-floor capability.

CNC Programming Technician — Develops Mastercam and Fusion 360 programs for production work, often supporting multiple machines across a shop.
CNC Setup Technician — Specializes in setup of complex jobs including soft-jaw work, tombstone fixtures, and multi-axis configurations; qualifies first articles for production.
Multi-Axis CNC Operator — Operates 4- and 5-axis equipment in aerospace, defense, medical-device, and precision-component shops.
Mechanical Design Technician — Bridges design and manufacturing functions, contributing fixture design, tool design, and design-for-manufacturability input.
Tooling Designer — Specializes in custom cutting tools, jigs, and fixtures for production environments.
Manufacturing Engineering Technician — Supports manufacturing engineers in process development, work-instruction creation, and continuous-improvement activities.
CNC Applications Specialist — Mid-career role with machine tool builders, CAM software vendors, and tooling manufacturers supporting customer implementations.

Florida and regional employer context. The 4- and 5-axis machining proficiency developed in ETI2419C is particularly relevant to Northwest Florida and Gulf Coast aerospace, defense, and shipyard employers, including Naval Air Station Pensacola and the Fleet Readiness Center Southeast detachment (depot-level aviation maintenance, including engine and structural component work), ST Engineering MRA (Pensacola), L3Harris Technologies, BAE Systems shipyards, and GE Vernova / GE Renewable Energy wind-component operations. Broader Florida aerospace-defense employers with multi-axis CNC needs include Lockheed Martin (Orlando and Eglin), Northrop Grumman, L3Harris (Melbourne and Palm Bay), Boeing-related Space Coast operations, Embraer Executive Jets (Melbourne), and SpaceX launch and refurbishment operations on the Space Coast. Precision job shops and tool-and-die operations across Florida actively recruit graduates with documented multi-axis programming and setup capability.

Special Information

Course Format and Position in Curriculum

ETI2419C is delivered as an integrated lecture-and-laboratory course meeting in the CNC shop, with the 75 contact hours allocated approximately 15 hours of lecture and 60 hours of supervised laboratory work over a 16-week semester. The capstone-project orientation means lab work increases in independence and complexity through the semester, culminating in portfolio-quality projects suitable for use in employment interviews.

As the fourth-semester capstone of the Mechanical Design and Fabrication specialization, ETI2419C completes the sequence: EGN 1123 (Engineering Graphics) → ETI 2411C (Mechanical Design CAD) → ETI 2414C (Computer Aided Manufacturing — Fusion 360) → ETI 2419C. Per the course description, ETI2419C also serves currently or previously employed CNC technicians seeking supplemental advanced training, and may be taken with permission of instructor for that purpose.

Certification Preparation

The course aligns with multiple industry-recognized credentials relevant to advanced CNC and CAM practice:

Mastercam Certified Professional: Credentialing pathway aligned to Mastercam University online curriculum integrated into the course.
Advanced Autodesk Manufacturing credentials: Builds on the Associate-level credential introduced in ETI2414C.
NIMS Machining Level II (CNC Setup Programmer): Process-based credentials in CNC mill and CNC lathe programming that align with the advanced setup and programming work in this course.
SME Certified Manufacturing Technologist (CMfgT): Foundational SME credential covering manufacturing processes, materials, automation, and quality — supported by the capstone integration of these topics.
Haas Operator and Programmer proficiency: Documented experience on current-production Haas mill and lathe controls valued by regional employers operating Haas equipment.

Transferability Notice

ETI2419C is designated AS-only at Pensacola State College and does not satisfy A.A. transfer requirements. As a course currently offered at a single SCNS institution, transferability to other Florida College System schools or to the State University System is at the discretion of the receiving institution. Students intending to apply credits earned in this course toward another program should consult an advisor at the receiving institution. Articulation into Bachelor of Applied Science (BAS) programs in Engineering Technology or Supervision and Management at Pensacola State and elsewhere is the most common continuation path; articulation into traditional engineering BS programs is uncommon and should not be assumed.

Capstone Expectations

The capstone-project portfolio is the principal evaluation vehicle for this course. Students should expect to invest substantial out-of-class time on project documentation, setup-sheet preparation, and shop work beyond scheduled lab hours. Faculty typically encourage projects that students can use as work samples for employer interviews. Industry advisory input is reflected in project selection, with emphasis on demonstrating multi-axis programming, fixture design, and combined mill-and-lathe workflow.

AI Integration

Modern CAM platforms used in this course incorporate AI-assisted capabilities that students will encounter as part of advanced workflow practice:

Mastercam Dynamic Motion and Autodesk's Fusion Adaptive Clearing use algorithmic strategies to maintain constant tool engagement and chip load, increasing material removal rates while protecting tool life. Students should understand the underlying principle (engagement-controlled toolpath) rather than treating these as black-box buttons.
Generative design for fixture and custom tooling components is an emerging optional area where AI-assisted topology optimization can propose fixture or tooling geometry meeting weight, strength, and fabrication constraints. As with all generative output, results require engineering review and verification before fabrication.
AI-assisted programming tools, including general-purpose code-explanation assistants, can help students understand unfamiliar G-code constructs, debug macro programs, and identify optimization opportunities. The verification chain — simulation, dry run, first-article inspection — remains the operator's responsibility regardless of AI assistance.
Predictive maintenance AI is increasingly common on production CNC equipment, monitoring spindle load, vibration, and other signals to predict tool wear and machine condition. Students entering modern shops should expect to interact with these systems.

The fundamental responsibility for the manufactured part — its dimensional conformance, its surface finish, its freedom from collisions or scrap — remains with the technician operating the machine. AI assistance increases the technician's leverage; it does not transfer the responsibility. Graduates of ETI2419C should leave the course able to use AI-augmented CAM and CNC tools competently and able to articulate the verification practices that distinguish responsible advanced manufacturing from over-reliance on automated tooling output.