C.R. Onsrud CNC Upgrade: How General Stair Saved 8,000 Files with a MachMotion Retrofit

Upgrading your CNC router doesn’t mean starting over. Instead, it means choosing the right path forward.

General Stair Corporation, a premier stair manufacturer in Florida, faced a critical challenge: their 2004 C.R. Onsrud 288G16 CNC router was running on outdated controls that were becoming unreliable, unsupported, and nearly impossible to find parts for. With over 8,000 custom part files built over decades, the team feared that upgrading their CNC controls would mean starting from scratch. Fortunately, MachMotion’s CNC retrofit solution allowed them to modernize without rewriting a single file. This is the story of how General Stair preserved their legacy CNC router, avoided costly downtime, and took control of their future with a smart CNC control upgrade.

CNC Router Obsolescence: The Hidden Risk for Stair Builders

The team at General Stair knew it was time for a change. One looming question held them back: What happens to the 8,000+ part files we’ve built over the years?

The fear of losing decades of work, thousands of custom part files, finely tuned tool paths, and hard-earned production knowledge because their CNC control system was no longer supported was alarming. These files weren’t just data, they were the backbone of their business. Rewriting them for a new machine would have meant months of downtime, skyrocketing costs, and the very real risk of production errors that could damage their reputation and bottom line. 

Securing A Future With Simple & Modern CNC Controls

General Stair found their solution to their obsolescent controls with MachMotion. At the heart of the solution was the MachMotion GC-Adaptor. The GC-Adaptor is a powerful feature that seamlessly translates existing cut files into industry-standard RS-274 G-Code, allowing you to run your trusted toolpaths, offsets, macros, and subroutines without modification.

No rewriting part files – Keep using the same part files you already have.
No workflow disruptions – Your trusted programs will run exactly as expected.
No trial-and-error guesswork – Eliminate  the risk of costly reprogramming mistakes.

It was the solution they were hoping for! A way to bring their trusted C.R. Onsrud CNC router into the modern era without giving up the years of work, time, and craftsmanship stored in their part library. There was no need to touch the post processor, and no lost time reprogramming existing jobs. They were able to keep production moving with minimal disruption.

C.R. Onsrud CNC Upgrade with MachMotion Controls

The aging control system on the Onsrud 288G16 was upgraded with MachMotion’s 2000 series controller. The industrial Windows-based control is intuitive to use and has added features over the original system including faster file loading, better diagnostics, modern touchscreen operation, and simplified operator training. And thanks to the GC-Adaptor, General Stair’s part files worked right out of the gate. 

• Zero File Conversion: The GC-Adaptor made it possible to use all 8,000+ legacy files as-is.
• Simple, Modern Controls: The intuitive touchscreen interface made training their team and operating the controls so much easier.
• Future-Proofing With 20-Year Parts Guarantee: With dedication to long-term support and new hardware, downtime concerns dropped significantly.
• U.S.-Based Lifetime Customer Support: Fast, responsive help from MachMotion’s U.S.-based technical team, both during and after the install.
• 1-Year Parts Warranty: All new products are warranted to be free from manufacturer defects for one year from the date of purchase.

The team at General Stair now has a modern CNC control platform that makes their C.R. Onsrud router easier to run and maintain, without losing what made their production line efficient in the first place. With their Onsrud CNC upgrade, they can now run their trusted machine for years to come. For other stair manufacturers or custom woodworking shops in a similar situation, let us do the same for you!

Helping Stair Manufacturers Modernize With Confidence

If you’re a stair manufacturer or custom woodworking shop relying on an aging CNC router or other CNC machine, don’t face the fear of obsolescence alone. Just like we did for General Stair, MachMotion will help you upgrade with confidence. We’ll put an end to your worries about preserving the part files you’ve built over years of hard work and unexpected downtime. 

Whether you’re running a legacy C.R. Onsrud router or another older system, our retrofit solutions are designed to keep your shop running smoothly without sacrificing what you’ve already built. Don’t wait for a failure to force your hand. Let us help you take control of your future today.