The Challenge: 

HRC operates in one of the most demanding manufacturing environments in the world: professional motorsports, where timelines are compressed, and performance expectations are extreme. Engines must deliver power while meeting strict durability targets, ranging from approximately 2,500 miles in IndyCar to up to 4,500 miles in endurance sports car racing. 

At the same time, teams are constantly pushing the limits of performance: 

• Designs must balance durability with weight and efficiency 

• Failures must be diagnosed and corrected immediately 

• New parts often need to be designed, machined, and tested within days 

There are times when issues discovered during dyno testing result in a rapid response: 

• We need to change this on the component 

• Update the program and machine the part 

• Have a new version running as soon as the next day 

This level of speed requires seamless collaboration between engineering, programming, and manufacturing, all without sacrificing precision.

The Solution: 

HRC uses Mastercam across its machining operations to program, simulate, and validate a wide range of complex components. From Mill-Turn parts to full 5-Axis geometries, Mastercam enables the HRC team to bring designs to life efficiently and reliably.

Key capabilities include: 

• Advanced Multiaxis programming Programmers use unified, morph, and blade-focused toolpaths to machine intricate geometries such as swirl vanes and impellers. 

• Mill-Turn integration Mastercam supports complete workflows on multitasking machines, allowing parts to be completed in a single setup. 

• Full simulation and verification Teams simulate entire machining processes, from turning through milling, ensuring confidence before running on the machine. 

• Seamless workflow from programming to production By validating toolpaths and setups in advance, operators can get on the machine with a lot of confidence, reducing risk and speeding turnaround. 

This integrated approach allows HRC to move from concept to finished component rapidly, while maintaining the accuracy required for high-performance racing.

Results: 

Speed and Responsiveness 

Mastercam enables fast iteration cycles, allowing teams to respond to testing results and implement design changes in as little as one day. 

Confidence in Machining 

With comprehensive simulation and toolpath control, programmers and operators can run complex parts with assurance, minimizing errors and rework. 

Optimization of Performance 

By supporting precise control over geometry and machining strategies, Mastercam helps engineers refine components for both durability and peak performance. 

Versatility Across Applications 

From simple lathe operations to advanced 5-Axis machining, Mastercam supports a wide range of manufacturing needs within a single platform.

Dynamic, Innovative Workflow 

The flexibility of Mastercam allows HRC to use it in many ways, keeping workflows adaptable and aligned with evolving design demands.