DesignWithAjay’s Checklist for Converting CAD to CAM Without Errors

At Ajay Industries, we design with manufacturing in mind. Whether you’re prototyping a twin-shaft shredder or preparing a gearbox housing for CNC machining, converting your CAD model to CAM must be done with precision. A single oversight—like a missing tolerance or overlapping geometry—can lead to toolpath errors, wasted material, or machine crashes.

This checklist ensures your CAD files are clean, complete, and CAM-ready, streamlining the transition from design to production.

Step-by-Step CAD to CAM Conversion Checklist

1. Finalize the CAD Model

• Ensure all bodies are solid and watertight
• Remove hidden sketches, construction geometry, and unused features
• Validate geometry using “Check” tools in SolidWorks or Fusion 360

Ajay Tip: Use part simplification tools to remove cosmetic fillets or logos that don’t affect machining.

2. Set Units and Scale

• Confirm model units match your CAM software (typically millimeters or inches)
• Standardize across assemblies to avoid scaling mismatches

Ajay Tip: Use global variables to control key dimensions and ensure consistency across variants.

3. Assign Manufacturing Tolerances

• Apply tolerances to critical features (holes, fits, slots)
• Use ISO or ANSI standards for clarity
• Include surface finish symbols where needed

Ajay Tip: Link tolerances to your BOM for traceability and procurement alignment.

4. Clean Up Geometry

• Eliminate overlapping edges, duplicate faces, and zero-thickness surfaces
• Flatten Z-axis for 2D profiles (especially in DWG exports)
• Convert splines and ellipses to arcs or polylines for CNC compatibility

Ajay Tip: Use “Overkill” and “Flatten” commands in AutoCAD or mesh repair tools in Fusion 360.

5. Define Machining Features

• Identify pockets, contours, holes, and bosses
• Tag features with machining operations (e.g., drill, mill, bore)
• Group features by tool type or setup stage

Ajay Tip: Use CAM templates or feature recognition tools to automate toolpath generation.

6. Export Correct File Formats

• For 3D machining: Export STEP, IGES, or native SolidWorks files
• For 2D profiles: Export DXF or DWG with clean layer structure
• For mesh-based CAM: Export STL with fine resolution and binary format

Ajay Tip: Always inspect exported files in a viewer before importing into CAM.

7. Simulate Toolpaths

• Run dry simulations to check for collisions, overcuts, and tool reach
• Validate feed rates and spindle speeds against material specs
• Confirm fixture and stock setup matches real-world conditions

Ajay Tip: Use SolidWorks CAM or Fusion 360’s Manufacturing workspace for integrated simulation.

Real-World Example: Shredder Shaft CAM Prep

CAD Model: Twin-shaft with keyways and bearing seats CAM Process:

• Cleaned geometry and flattened Z-axis
• Assigned tolerances to bearing fits
• Exported STEP and DXF for multi-axis machining Outcome: Zero toolpath errors, 100% dimensional accuracy, reduced setup time

What You Get with Every DesignWithAjay CAD File

• Fully parametric models with machining annotations
• BOM with material specs and tolerance callouts
• Exploded views and setup drawings
• CAM-ready exports (STEP, DXF, STL)
• Revision history and manufacturing notes