From minutes to seconds - a full performance overhaul of BPS
This project combined two parallel performance optimization efforts within BPS with the development of new CAD import functionality. The result is a significant reduction in wait times for bending machine operators, along with greater flexibility in integrating BPS with clients’ existing design assets. The recommended optimizations have been rolled out to production, with regression tests confirming the achieved performance gains.
- 75-85%faster processing across both bottlenecks
- 13+ minworst-case 3D model generation before the fix, now single-digit seconds
- 3CAD formats now imported directly: DWG, DXF and STEP
Overview
- Diagnosed two independent bottlenecks: 3D busbar model rendering and the bending animation process
- Ran dozens of test scenarios across models with 10 to 300 holes and varying bend counts
- Processing time grew non-linearly - up to 13+ minutes for the 3D model and 64 seconds for the bending animation (170 holes)
- Extended BPS with model import support for DWG, DXF and STEP files
- Achieved a 75-85% performance improvement across both areas
BPS - ERKO's proprietary application, Busbar Processing Software - supports the busbar production process, from designing a 3D model of the busbar, through multi-hole punching, to animating and executing the bend on the machine. As order complexity grew, operators started hitting longer, UI-blocking waits both while generating the 3D model and while preparing the bending animation - a single process at the client could stretch to over ten minutes. In parallel, ERKO needed the ability to import existing technical documentation directly into BPS without manually recreating models. 54Soft carried out an in-depth performance analysis of both processes and extended the application to support common CAD formats.
How it works
Measure
Dozens of test scenarios across models with 10-300 holes and 1-3 bends, timing every stage of both processes.
Diagnose
Both slowdowns traced to one root cause: per-hole geometry generation and a full collision-model rebuild on every change.
Optimise
Batched hole creation, cached collision validation, and model and animation generation moved to a background thread.
Extend
Import support for DWG, DXF and STEP, so existing CAD documentation loads straight into BPS.
Solution & Result
We analyzed both processes using test sets spanning models with a growing number of holes (10-300) and bends (1-3), measuring the time spent in each stage: model loading, hole generation, animation frame rendering, and collision validation. In both cases we found the same pattern: processing time grew exponentially with the number of holes, while the number of bends had no meaningful effect. For the 3D model, generation time reached over 13 minutes at 300 holes; in the bending process, for a busbar with 170 holes, hole generation and frame rendering took 64 seconds - 99% of the total animation time. This pointed to a shared root cause: sequential, per-hole geometry generation instead of batched operations, plus a full rebuild of the collision model on every change.
We recommended replacing sequential hole creation with a single batched operation (ExtrudeRemoveThroughPattern), caching collision validation, moving model and animation generation to a background thread, and unblocking the UI when switching tabs so operators no longer have to wait for a full preview before starting work. Implementing these changes delivered a 75-85% performance improvement, cutting processing time for the largest models from several minutes down to single-digit seconds. Independent of the optimization work, we extended BPS with import support for DWG, DXF and STEP files, letting ERKO's customers load their existing CAD documentation directly into the application without manually recreating busbar geometry.
What the client says
I wholeheartedly recommend working with 54Soft, who demonstrated a high level of professionalism, commitment, and flexibility throughout the execution of the tasks entrusted to them.
Read the full recommendation
Throughout the collaboration, all agreed fixes and modifications were delivered on time, and the response to emerging changes and new requirements was quick and effective.
The team showed great openness to dialogue, while also proposing solutions that supported achieving the project's goals.
The way the work was documented deserves particular recognition.
The scope of the changes made was prepared in a clear, complete way that matched the agreed requirements, which significantly simplified tracking progress and making project decisions.
I also rate the culture of collaboration and communication highly. Meetings were conducted professionally, efficiently, and to the point, and information flowed smoothly at every stage of the project.
As a result, the collaboration was marked by a high degree of transparency and mutual trust.
The company is a reliable and trustworthy business partner, whom I can wholeheartedly recommend for projects that require punctuality, flexibility, high-quality documentation, and a professional approach to the client.
Sławomir MichalskiHead of the Construction Department, ERKO
