A system that uses a quick tap test to calibrate computer numerical control machines is boosting productivity for U.S. manufacturers — and saving time, money and energy in the process.
Why it matters:
Machined parts are everywhere — in cars, appliances, medical devices and more. Improving the efficiency of machined part production will reshape manufacturing across the country.
Real-world impact:
The U.S. Department of Energy’s Oak Ridge National Laboratory, or ORNL, and MSC Industrial Supply developed MillMax, an R&D 100 Award winner. The system is already in the hands of hundreds of U.S. machinists, trained by MSC and equipped with portable toolkits. The system:
- Cuts calibration time from hours to minutes
- Improves tool performance without using extra material
- Helps machine shops of all sizes push the limits of speed and precision
The benefits:
- 300% average improvement in material removal rates
- 50% average decrease in cycle times
- $38 million in profit improvement so far with an estimated $750 million in projected annual savings if adopted across the industry
- $24,000 in average savings per company • 100 hours gained in capacity and efficiency
- Reduces scrap, energy use, and lead times
- Enables energy savings of 1.87 billion kilowatt-hours per year if scaled
The innovation:
MillMax is a calibration system that uses modal tap testing to map out ideal cutting conditions in minutes. The system works by:
- Placing an accelerometer on the cutting tool
- Striking the tool with a modal hammer
- Analyzing vibrations to identify the most stable cutting conditions
MillMax generates a clear map of spindle speed and cutting depth — helping machinists run faster, smoother, and with less waste.
Backed by science:
This work was supported by the U.S. Department of Energy’s Advanced Materials and Manufacturing Technologies Office.
- Developed at DOE’s Manufacturing Demonstration Facility, or MDF, at ORNL
- Delivered to industry through a partnership with MSC
Deep dive:
Read more about the MillMax system. Learn about the MDF Technical Collaboration Program and how the MDF is accelerating manufacturing innovation.
The big picture:
From lathes to milling to drilling, a simple tap test is unlocking smarter, faster, and more energy-efficient manufacturing across the U.S.