How did CNC Solutions help Mathews Archery increase production?

CNC Solutions designed two automated machining cells using FANUC robots and Haas CNC machines. These cells enabled unattended operation, including weekends, resulting in a 25% annual increase in riser production by running up to six extra shifts per week without additional staffing.

What specific technologies were used in the automated cells for Mathews Archery?

The first cell featured a FANUC M-20iD/12L robot on a 7th-axis rail servicing five Haas UMC-1000SS machines for finishing operations. The second cell used a FANUC M-710iC/50 robot on a 7th-axis rail with six Haas VF-3YT machines, including custom dual-gripper tooling, automated conveyors, and a traveling regrip station for efficient handling of aluminum forgings.

What were the key results of the robotic automation for Mathews Archery?

The automation led to a 25% boost in riser production, a 50% reduction in scrap, improved safety by eliminating heavy lifting and misloading errors, and a quick return on investment (ROI) of just 1.5 years per cell. It also allowed for flexible handling of multiple bow models and design updates.

How did the automation address labor shortages at Mathews Archery?

By enabling 16-24 hours of unattended operation, the robotic cells reduced the need for constant operator attention, freeing employees for more skilled tasks. This helped Mathews maintain production goals without overburdening their 375-person workforce, even allowing for weekend runs while keeping Sundays off.

How does robotic machine tending improve quality and safety in archery manufacturing?

Robotic tending minimizes human errors like misloads, reduces setup times, and eliminates ergonomic risks from heavy lifting. In this case, it also incorporated in-machine deburring and air blasts for coolant removal, leading to higher precision, 50% less scrap, and a safer work environment.

Robotic Cells Transform Archery Bow Manufacturing Efficiency

Customer:  Mathews Archery

Location:  Sparta, Wisconsin

Customer Business Issue:  Limited capacity and rising demand

Solution:  CNC Solutions machine-tending automated cells

Results: 25% increase in production, 50% less scrap

Return on Investment: 1.5 years per cell

Raw bow riser forgings for Mathews Archery travel along the conveyor, ready for the FANUC robot to transfer them to the next operation. This is part of a CNC Solutions’ automated cell designed to boost production. All images courtesy of CNC Solutions LLC.

Known for pioneering innovations like the single-cam system, Mathews Archery manufactures bows trusted by hunters and competitive archers worldwide. At the heart of every bow is the riser, a rigid central frame requiring precision and the strength to support critical components. Each year, Mathews releases two to seven of their new bow models, sustaining high demand and keeping the archery community eager for the next innovation.

As demand for bows grew, Mathews’ production lines faced mounting challenges. Manual machine tending struggled to keep pace with rising orders, and ongoing labor shortages added pressure to the 375-employee company. Mathews needed a solution to increase capacity without overburdening employees—ensuring they could enjoy weekends off while honoring the Christian company’s commitment to remain closed on Sundays.

“We currently work five days a week, 24 hours a day, and sometimes on Saturdays, yet we still fall short of production goals,” said Mathews Archery Machine Shop Technology Development Manager Scott Jenkins. “We needed a system that could run unattended on Sundays and, if necessary, handle weekend production as well.”

Turning to CNC Solutions

The FANUC robot lifts a raw forging from the conveyor. CNC Solutions’ automated cell eliminates ergonomic challenges and misload risks for these 12.5-pound aluminum parts.

Having partnered successfully with CNC Solutions in the past, Mathews Archery once again turned to the Wisconsin-based automation integrator for its expertise in robotic machine tending.

Founded in 2000 and located between Madison and Milwaukee, CNC Solutions specializes in robotics integration and turnkey machine-tending systems that enhance precision, consistency, and productivity across manufacturing operations.

“We’ve worked with them on multiple projects,” said Jenkins. “It’s about the relationship—when you work well with someone, they understand your processes, and you know what they’re capable of delivering. They handle the turnkey systems, while we supply our own tooling, programming, and conveyors when needed. It’s a true partnership.”

In 2025, All World Machinery Supply, a Northern Illinois–based machine tool solutions provider, acquired CNC Solutions to broaden its automation offerings, merging All World’s workholding and hydraulics with CNC Solutions’ robotics to deliver fully integrated solutions that help manufacturers boost efficiency.

CNC Solutions previously engineered two automated machining cells for Mathews’ riser production, led by Lead Automation Technician Steve Shearier, Mechanical Engineer John Brebeck, and Lead Robotics Programming Engineer Ryan Runke, demonstrating the company’s ability to combine innovation, precision, and labor-saving automation in real-world manufacturing.

To optimize labor savings and return on investment, CNC Solutions engineered two new automated machining cells for Mathews’ riser production, led by Lead Automation Technician Steve Shearier, Mechanical Engineer John Brebeck, and Lead Robotics Programming Engineer Ryan Runke.

First Automated Cell

The FANUC robotic arm lifts a raw bow riser forging from the conveyor for machining. Designed for flexibility, the CNC Solutions cell can process multiple riser models and adapt to frequent design updates without slowing production.

The first cell focused on Operation 20, where rough-machined risers are finished. Engineers integrated a FANUC M-20iD/12L robot mounted on a 7th-axis rail to service five Haas UMC-1000SS machines. The system eliminated a third machining operation, automated in-machine deburring, and reduced operator strain.

Additionally, operators maintained the flexibility to run machines manually when needed. A robot-guided vision system simplified raw-part loading, while custom automatic side doors allowed the robot to access each machine without disrupting manual operations.

“We spent considerable time simulating the robot’s motion to ensure the design worked within the tight clearances,” Runke said.

The first cell achieved a full return on investment in just 18 months.

Second Automated Cell

A FANUC robot handles remanent removal on Operation 20, finishing rough-machined risers with precision. Automation has boosted quality, reduced scrap, and streamlined Mathews Archery’s riser production.

Mathews again partnered with CNC Solutions to develop a second automated cell. This stage handled 28–33-inch aluminum forgings weighing up to 12.5 pounds. The parts posed ergonomic challenges, remanent removal, constant operator attention, and carried a higher risk of misloads that could compromise machining precision.

The cell centers on six Haas VF-3YT machines, serviced by a FANUC M-710iC/50 robot mounted on a 7th-axis rail for extended reach. It was designed to run 16 hours unattended, minimizing operator intervention. Material flow is fully automated: raw forgings arrive via two infeed conveyors, and the system can process two models simultaneously. Finished parts move to outgoing conveyors for minor hand deburring, about two minutes per riser, before proceeding to the next automated cell for Bridge-Lock™ machining.

“The system allows us to load raw forgings on Friday and retrieve finished risers by Monday, while still managing other tasks.”

The cell supports a two-step machining process: raw forgings are machined, flipped, and machined on the opposite side. Air blasts remove coolant between operations, which include drilling, milling, tapping, and partial in-machine deburring. Custom dual-gripper tooling allows the robot to handle raw and finished parts in a single motion, reducing cycle times and minimizing manual handling.

Instead of a fixed regrip station, CNC Solutions engineered a traveling regrip station mounted to the robot carriage, saving open-door time and improving efficiency. Inspection drawers at each machine enable operators to perform random quality checks without interrupting production.

The system was built for flexibility to accommodate evolving bow designs. “We future-proofed it by making a fixtured pallet removable on the regrip station so new parts can be added as needed,” said Brebeck.

Results: Higher Production, Lower Scrap

The finished riser from Operation 20 is lifted off the fixture by the robot. Having CNC Solutions automate this step frees operators to perform higher-value tasks.

The flexibility and reliability of the system enable Mathews to meet demand while maintaining quality and safety.

“The system allows us to load raw forgings on Friday and retrieve finished risers by Monday, while still managing other tasks,” Jenkins said. “It’s reduced labor demands and freed our operators to focus on more skilled work.”

The two cells, spanning 11 CNC machines on 75-foot rails, can run 24/7 on weekends or up to six extra shifts per week, producing 25% more risers annually. Scrap has been cut in half, and each cell achieved a 1.5-year ROI.

Automation has also improved safety and quality: misloading errors and setup times have been reduced, heavy lifting and feeler-gauge setups eliminated, and over/under conveyors keep the work area organized. The system can accommodate multiple riser models and frequent design updates without slowing production.

For Mathews, the push for automation to match rising product demand will continue to support its strong sales trajectory. And with this CNC Solutions-engineered system alone, production efficiency has effectively doubled.