Sparky's Woodworks Doubles Production with New DWC2636 CNC Machine

Jan 10

Sparky's Woodworks, owned by James Sparks, is a thriving business located in Fletcher, Missouri, USA. Specializing in high-quality precision carved signs, gifts, and more for both homes and businesses, Sparky's Woodworks has built a reputation for craftsmanship and attention to detail. The company’s online presence is solid, with an active store and social media showcasing their finely crafted products.

The Challenge:

James had been using a DWC2440 CNC machine for over four years to produce a wide range of precision carvings.

“Ordered our DWC2440 in January 2020 and picked it up in February at the Woodworking Show in Collinsville, IL. It’s been slamming ever since! Started in our basement and added a new shop building in 2022. Yesterday, just in time for our 5th birthday, we became a 2-DWC shop. Spent today tidying up after delivery day chaos and learning the new machine with Laney. Back in business soon with double the production capacity. Super-stoked and a happy DWC customer. Thanks, Laney, Burl, & Jim! Cheers to the next 5 years!”

While the machine served him well, James found himself reaching the limits of its capacity and efficiency, especially as his business grew. To increase his production capacity, improve efficiency, and meet demand, James needed a machine that could handle larger volumes and more complex tasks.

The Solution:

After careful consideration, James upgraded his equipment by purchasing the DWC2636 CNC machine. The larger, more powerful machine promised to provide the speed and reliability James needed to increase his production.

“I had my 2440 for about 4.5 years before adding a 2636. I had sort of gotten set in my ways of doing things, so it came as a surprise when Laney showed me a different way of surfacing the spoilboard when we set up my 2636. Instead of going around in a square pattern cutting in all directions using a pocket cut, we did profile cuts on single lines so the machine only cut in one direction.”

Despite being familiar with his previous DWC2440, James found the new DWC2636 offered faster speeds, smoother cuts, and a significant boost in his ability to handle larger jobs with ease.

“I started with a batch of 25 small food boards (9x14) as my first test project. The machine made light work of them, completing the intricate v-carve with impressive speed and precision.”

*“My first carve on DWC2636 sitting on top of the next 25 carves. The 2636 made light work of those food boards! Fast, clean, consistent. Super stoked.”* - James shared

Benefits:

Increased Production Capacity

The addition of the DWC2636 allowed James to run both machines simultaneously, effectively doubling his production capacity.

“With two machines now, I can run them both at once, doubling my output. I'm more than happy with my decision to upgrade to the DWC2636!”

This upgrade was especially critical as James had recently seen a surge in orders. With two CNC machines in operation, he could fulfill more customer requests in a fraction of the time it previously took.

Improved Efficiency and Speed

James noticed a dramatic increase in the machine’s cutting speed and overall efficiency.

“I had no idea my bits were capable of moving so fast! Sometimes it’s scary. ‘Quiet’ is not a word I’d use to describe the 2636. I thought the 2440 was loud. The 2440 sounds almost silent compared to the 2636 when it’s running. It’s cool though, it sounds like an industrial machine.”

“When it’s sitting still, the 2636 is quieter than my 2440—you can barely hear the fan and water pump. But as soon as the carving starts, you can’t even hear the 2440 running over the 2636. I guess it’s just the nature of the screw drives and the more powerful motors.”

The surfacing and roughing processes, which typically took several hours on the 2440, were completed in much less time on the DWC2636.

More Consistent Results

James quickly found that the DWC2636 provided more consistent results across the board. Whether he was carving food boards or precision signs, the machine delivered a higher level of accuracy and fewer imperfections in the final product. This consistency helped increase customer satisfaction and repeat business.

Ease of Setup and Use

Though James had already been using a CNC machine for years, the transition to the DWC2636 was seamless, thanks to the helpful guidance from Laney and the user-friendly setup.

“Things aren’t where they usually are, I’m tripping over stuff, but I’m loving having both machines running at once.”

Conclusion

Sparky’s Woodworks has seen substantial growth and efficiency improvements since adding the DWC2636 to their shop. The larger, faster machine has allowed James to take on more work, improve production times, and deliver even better products to his customers.

The upgrade to the DWC2636 has proven to be a valuable investment, ensuring that Sparky’s Woodworks is prepared to meet growing demand and continue delivering exceptional quality for years to come.