From Concept to Chips: Delivering a Turnkey 4th-Axis Solution on a New Mazak VMC

We’re wrapping up a full turnkey machining solution for one of our Midwest customers—and this project goes far beyond a standard trunnion setup.

What started as a conversation about “adding a 4th axis” quickly turned into a complete process redesign: custom workholding, CAM programming for a complex casting, and on-machine installation and prove-out on a brand-new Mazak machining center.

This is exactly the kind of project our team loves—because it pulls together every part of what we do best.

The Challenge: A Complex Casting on a New Machine

Our customer had just invested in a new Mazak vertical machining center. Their goal was clear:

• Move a complex casting into production quickly

• Reduce the number of setups and manual handling

• Improve consistency and part quality

• Free up internal resources by outsourcing the engineering and implementation work

Like many shops, they didn’t just need a rotary table and a trunnion. They needed a complete, reliable process that would be ready to run on day one.

That’s where our turnkey approach came in.

Engineering a Complete Workholding System

The first step was to design the right foundation for 4th-axis production.

Our engineering team started with the part and the machine model, then built a workholding solution from the ground up:

• Custom trunnion/workholding layout tailored to the casting’s geometry and datum structure

• Fixture design focused on rigidity, repeatability, and clear tool access

• Vektek hydraulic workholding integrated to provide fast, consistent clamping and unclamping

• Rotary integration with a Koma Precision 4th-axis solution, matched to the Mazak and the customer’s torque and accuracy requirements

Everything was modeled in 3D so the customer could see exactly how the part would clamp, how tools would approach, and how the casting would be oriented for each operation. This eliminated guesswork and reduced the risk of surprises once we were on the floor.

CAM Programming for a Complex Part

With the workholding concept locked in, we moved into CAM.

The casting geometry demanded thoughtful toolpath strategies to balance cycle time, surface finish, and tool life. Our programmers:

• Built complete 4th-axis programs for all operations on the Mazak VMC

• Used dynamic/tool-engagement strategies where appropriate to keep the spindle cutting efficiently

• Sequenced operations to minimize repositioning, air cutting, and unnecessary tool changes

• Simulated toolpaths against the actual fixture and machine envelope to avoid collisions and clearance issues

By tying together CAM programming with the workholding design, we ensured that the process was realistic, repeatable, and ready for production—not just theoretical.

On-Machine Installation, Setup, and Prove-Out

This week, our team is installing the system and proving it out on the customer’s Mazak.

That on-site phase includes:

• Rotary and trunnion installation on the VMC table

• Indicating, leveling, and dialing in center height so the rotary and workholding system are properly aligned

• Setting up the fixtures and hydraulic workholding from Vektek, including hose routing and connections

• Loading and validating CAM programs at the control

• Running first-article parts and making any fine adjustments needed for optimal cycle time and finish

• Documenting setup procedures so the customer’s operators can reproduce the setup confidently

The hand-off doesn’t happen until parts are coming off the machine to print and the process is stable.

Why Turnkey 4th-Axis Solutions Matter

For many shops, adding a 4th axis is no longer just about buying hardware—it’s about buying capability.

A true turnkey solution like this delivers:

• Faster time to production – You’re not piecing together fixtures, programs, and tooling over months. The process arrives ready to run.

• Less burden on internal engineering – Your team can stay focused on other priorities while we handle the heavy lifting.

• Reduced risk and guesswork – Workholding, programming, and machine integration are all designed together by one team.

• Repeatable results – Documented setups, proven programs, and robust fixtures make it easier to scale and train new operators.

Instead of treating the rotary, trunnion, and fixtures as separate purchases, we treat them as one integrated system built around your parts and your machine.

Partners in Precision

Successful turnkey projects depend on strong partnerships. On this build, we’ve been proud to work with:

• Vektek, LLC – Providing the hydraulic workholding components that keep parts clamped securely and consistently

• Koma Precision Inc – Supplying the rotary solution that makes 4th-axis capability possible on the Mazak

Bringing the right partners together allows us to deliver a system that is not only accurate and robust, but also practical for day-to-day production.

Ready to Explore a Turnkey 4th-Axis Solution for Your VMC?

If you’re considering a 4th-axis upgrade for your vertical machining center, you don’t have to tackle it piece by piece.

We can help you with:

• Workholding and trunnion design

• Rotary integration

• CAM programming for your specific parts

• On-machine installation, prove-out, and runoff

From concept to chips, our team is equipped to deliver a complete solution that fits your machines, your parts, and your production goals.

If you’re exploring a turnkey 4th-axis solution for your VMC, let’s start a conversation. We’d be glad to help.