%20(3).png)
New England Airfoil Products (NEAP) plays a critical role in powering U.S. military and aerospace systems. From compressor blades in commercial engines to critical airfoil components for the U.S. Army’s AGT1500 engine—the heart of the Abrams tank—NEAP’s work supports some of the most demanding missions in the world.
As global pressures intensified and the Department of Defense called for greater throughput, NEAP needed to respond quickly—without expanding its footprint.
“In this business, demand comes in waves,” said Nik Delic, NEAP’s President of North America. “When the Army needs more engines, more blades, more capacity, we need to be able to flex immediately.”
For a company operating nine dedicated machining cells for a single product line, that flexibility required new efficiency, predictability, and insight.
That’s when NEAP tapped into the subject-matter expertise and physics-based optimization they needed to validate strategies upfront and move faster.
The Challenge: Scale Production Without Expanding the Floor
NEAP’s primary question wasn’t about adding machines or people. It was far more fundamental:
How do we get more out of the machines we already have?
The team needed faster cycles, stronger tool life, lower scrap, and better machine health. Over time, they tested almost every toolpath and optimization method available. Some helped; some didn’t—but nothing delivered the predictable, repeatable gains they needed.
So, when CCAT introduced them to Third Wave Systems’ Production Module, they approached it with healthy skepticism.
“We’ve tried just about every software tool out there,” Delic said. “So, when CCAT came in with something new, we didn’t know if it would be different.”
It was. Quickly.
Why Third Wave Systems — and Why CCAT
Third Wave Systems (TWS) is not another CAM package. It’s a physics-based optimization engine that models real cutting forces, heat, chip formation, and material behavior—validating toolpaths before any machine time is used.
For NEAP, that level of visibility was the missing piece.
CCAT helped accelerate adoption by providing:
- Demonstrations using NEAP’s own geometries
- Hands-on validation at the Advanced Technology Center
- Support integrating TWS into their workflows
- Engineering context grounded in machine behavior
“CCAT played a key role in bridging the gap,” said Delic. “They helped us understand the workflow and feel confident adopting a new tool.”
The Impact: Faster Cycles, Lower Scrap, Stronger Confidence
The results were immediate.
“Third Wave Systems brings us up to 50% savings in machining time. We can now produce almost two parts in the time it used to take to make one.”— Nik Delic
Tool life has increased. Scrap rates have dropped. Machine strain decreased. And the team gained data-backed insight they never had before.
The software gave us insights we’ve never had."
These gains translated into:
- Lower forces and reduced wear on high-value machines
- More consistent programming and fewer first-article issues
- Better predictability for thin airfoil geometry
- A more confident, capable engineering team
Engineering Manager Brian Jacobs summed it up:
“This turns weeks of manual work into something we can validate in under 10 minutes. It changes how we plan and how we ramp up.”
CCAT’s Perspective: Strengthening the Supply Chain Through Capability
Chief Technology Officer, Dr. Amy Thompson, sees NEAP’s success as part of a broader shift in manufacturing:
“Manufacturers are under more pressure than ever—expected to deliver faster, reduce costs, and support national defense readiness with, in some cases, the existing resources. Tools like Third Wave Systems give companies the insight and confidence they need to compete with a software and platform that works within their existing systems.”
— Dr. Amy Thompson, CTO, CCAT
Thompson emphasized that physics-based simulation and training go hand-in-hand. That’s why technologies like TWS are integrated into CCAT’s Digital Thread Lab curriculum—helping teams learn, apply, and adopt these tools strategically in real operations.
“We applaud NEAP for not staying static and for leading by example.”
Beyond ROI: Supporting the U.S. Army and Defense Readiness
For NEAP, the impact extends well beyond machining efficiency.
Their blades and airfoil components directly support the AGT1500 engine powering the Abrams tank. Faster throughput strengthens military readiness. Higher quality strengthens safety. And as a supplier with reserved Army capacity, NEAP must be able to flex immediately when requirements surge.
With TWS and stronger programming insight, the team can respond to those moments with confidence—without overtaxing machines or risking part quality.
Across the organization, the mission is understood: every part produced contributes to the safety and capability of soldiers around the world.
A Smarter Path Forward — For NEAP and the Region
Today, NEAP uses Third Wave Systems as a foundation for every new development. Simulation comes first. Machine time comes later. The result is faster planning, more stable processes, and a stronger, more resilient team.
CCAT continues supporting NEAP as a strategic partner—helping refine workflows, explore new tools, and strengthen capability as production demands evolve.
Through this partnership, NEAP is better positioned to meet defense needs and contribute to a stronger regional supply chain.
The Big Picture: Solving the Real Challenges Manufacturers Face
Across the industry, manufacturers face growing pressure to deliver more with the same people, the same machines, and tighter expectations. The companies that stay ahead are the ones that combine:
- Physics-based simulation
- Skilled, continuously trained teams
- Smart technology adoption
- Strong, trusted partnerships
Together, these elements boost throughput, reduce risk, and stabilize operations.
NEAP’s journey shows the impact of bringing these pieces together. With stronger programming insight, better predictability, and the ability to validate strategies digitally, their team can ramp faster and respond immediately when defense demands surge.
CCAT’s integrated support model helps manufacturers pursue this same path—connecting training, tools, and real-world applications so teams can modernize with confidence. For NEAP, this guidance strengthened their transition from skepticism to capability, and manufacturers across the region are following similar trajectories.
________________________________________
Learn More
Learn more about Third Wave Systems during Digital Manufacturing Training Week at CCAT.
________________________________________
Watch the Full Interview
Hear directly from Nik Delic and Brian Jacobs.
Learn more about New England Airfoils Products here
________________________________________
About Voices of Innovation
Voices of Innovation spotlights manufacturers embracing technology and training to drive performance, innovation, and competitiveness. Each story shares real-world lessons from companies preparing for the future of advanced manufacturing.
