For large-scale automotive mold production, precision alone is not enough—efficiency and repeatability are just as critical.
When THACO AUTO needed to improve machining quality while reducing manual finishing time, BCAMCNC delivered a BCM4025DL 5-axis CNC machining center tailored for complex mold applications.
The result: fewer setups, shorter production cycles, and significantly reduced manual workload.
The Client Background
- Company: THACO AUTO
- Location: Chu Lai, Vietnam
- Industry: Automotive manufacturing & assembly
As one of Vietnam’s leading automotive groups, THACO operates a fully integrated manufacturing system. Mold precision and production efficiency directly affect final vehicle quality.
The Challenge: Precision, Efficiency, and Scale
Automotive molds such as bumpers, dashboards, and interior trims require both large machining capacity and high surface quality.
Before upgrading their equipment, the customer faced:
- Multiple setups with 3-axis machines, increasing alignment errors
- High manual polishing workload, consuming a large portion of production time
- Difficulty maintaining consistent quality on large parts (3–4 meters)
- Limited capability for more complex geometries
These limitations made it difficult to scale production efficiently.
The Solution: BCM4025DL 5-Axis CNC Machining Center
Key configuration includes:
- Work area: 4000 × 2500 mm with extended Z-axis
- 5-axis head for multi-angle machining in one setup
- Industrial control system for stable motion
- Heavy-duty structure for long-cycle machining stability
From Equipment to Workflow Integration
This project focused not only on machine delivery but on making sure the solution worked in real production conditions.
Sample Testing Before Delivery
Sample parts were machined based on the customer’s drawings before shipment, allowing verification of machining quality and toolpath strategy in advance.
Post-Processor Optimization
The system was matched with the customer’s existing CAM software (Powermill/UG), ensuring smooth operation without additional adjustments.
On-Site Installation and Calibration
During installation, the machine was calibrated across the full working range to maintain accuracy on large parts.
Operator Training
Training covered practical 5-axis operation, toolpath usage, and methods to reduce manual finishing time, helping the team quickly adopt the new process.
Operational Results
After integrating the BCM4025DL into production, the customer achieved:
- 75% reduction in part repositioning, improving setup efficiency
- Up to 60% reduction in manual sanding time
- More consistent surface quality on complex molds
- Ability to process large FRP trimming and foam patterns in-house
These improvements helped shorten delivery cycles and reduce reliance on manual work.
Why This Upgrade Matters
In large mold manufacturing, time is often lost in:
- Repositioning workpieces
- Manual finishing
- Correcting inconsistencies
A 5-axis machining approach reduces these inefficiencies by enabling more complete machining in a single setup.
A Practical Decision for Scalable Production
For THACO AUTO, adopting a 5-axis solution was a practical step toward improving production efficiency without increasing complexity.
By combining stable machine performance with application support, the BCM4025DL became part of the production workflow rather than just an additional machine.
Considering a Similar Upgrade?
If your current process still relies heavily on multiple setups or manual finishing, it may be limiting both efficiency and output quality.
A properly implemented 5-axis CNC solution can help reduce production time, improve consistency, and expand manufacturing capability.
BCAMCNC works with manufacturers to match machine configuration with real production needs, ensuring that the investment delivers practical and measurable results.
