MasterControls

What MasterControls does

MasterControls is a privately held CNC systems integrator founded in 2003 and headquartered in New Castle, Indiana, specializing in retrofit and rebuild services for legacy industrial machine tools. The firm provides onsite turnkey solutions that upgrade outdated or unsupported CNC controls on mills, lathes, boring machines, grinding machines, routers, shapers, hobbers, and planer mills, serving machine tool owners across 32 U.S. states. Its core technology centers on integrating third-party control platforms — Fanuc, Siemens (SINUMERIK ONE, 840D sl, 828D, 808D), and NUM (Flexium+ series) — into existing machines, with options ranging from full digital retrofits that replace all components to cost-effective analog retrofits that retain existing drives and motors. The firm also offers PLC upgrades, AC/DC drive replacements, hydraulic axis control via Delta Computer Systems controllers, and DIY retrofit kits for select applications.

The business model is project-based professional services combined with hardware resale. Revenue is generated from custom-quoted retrofit projects (typically 8-12 weeks from order to completion for medium-size jobs), component and control system sales, and project management fees for mechanical rebuilds subcontracted to partner firms. The firm operates an enterprise field sales motion with no public marketing beyond a website, phone line, and detailed RFQ form, relying on direct engineer-to-customer engagement and an in-person site assessment process. Mechanical work is referred to a curated network of machine tool rebuilders across the U.S. and Canada (including Line Machine in Canada and Industrial Machine Tech in Michigan), with MasterControls retaining overall project management responsibility.

MasterControls has completed over 350 retrofit and rebuild projects since 2003 with a staff of 1-10 employees, including a senior Controls Engineer with more than 30 years of CNC retrofit experience. Customers span diverse industrial verticals — aerospace parts, forging and machining, wood products, mining machinery remanufacturing, pump manufacturing, gear hobbing, and additive manufacturing — with no anchor customer concentration and no disclosed institutional ownership, venture funding, or M&A activity.

Name

MasterControls

Legal name

MasterControls, LLC

Website

https://mastercontrols.net

Company type

Private

Founded year

2003

Operating status

Operating

Headcount range

1–10 employees

Short description

MasterControls is a privately held CNC systems integrator that retrofits and rebuilds legacy industrial machine tools using Fanuc, Siemens, and NUM control platforms. It serves manufacturers across 32 U.S. states with onsite turnkey upgrade services.

Ownership category

akta.pro rank

Product category

CNC Machine Tool Retrofits

NAICS

Electronic and Precision Equipment Repair and Maintenance (811210), Relay and Industrial Control Manufacturing (335314), Switchgear and Switchboard Apparatus Manufacturing (335313), Engine, Turbine, and Power Transmission Equipment Manufacturing (3336)

SIC

Machine Tools, Metal Cutting Types (3541), Industrial Instruments For Measurement, Display, And Control (3823), Services-Computer Integrated Systems Design (7373), Switchgear & Switchboard Apparatus (3613)

akta.pro primary industry

CNC Machine Tools (Turning, Milling, Machining Centers) (IMAHADAA)

akta.pro secondary industries

Controls, Instrumentation & DCS/SCADA Retrofits (Plant & Grid) (EUAEALAB), Plant Electrical Systems Upgrades (Aux Power, MCCs, Cabling, Earthing) (EUAEALAJ)

Keywords

• CNC retrofit services
• Machine tool rebuilding
• PLC upgrades
• Motion control integration
• Control system retrofits

Headquarters

HQ city

New Castle

HQ country

United States

HQ region

North America

Offices1 record

Markets served

GTM type

B2B

Offering type

Services

Cost components

Personnel, Supply Chain, Operations, Technology or R&D, Marketing or Sales, Infrastructure

Revenue model

1. CNC Retrofit Projects: Project-based revenue from complete CNC retrofits including control systems, drives, motors, operator stations, and commissioning. Projects range from control-only upgrades to full turnkey solutions. Typical medium-size projects take 8-12 weeks from order to completion.
2. Hardware and Component Sales: Sales of CNC control systems (Fanuc, Siemens, NUM), servo motors, drives, IO modules, operator stations, and related electrical components as part of retrofit projects.
3. PLC Upgrades and Drive Replacements: Upgrading relay or outdated PLC machines and providing cost-effective drive replacement solutions for AC and DC motors. Lower-cost services compared to full CNC retrofits.
4. Mechanical Rebuild Coordination: Referral and project management services for mechanical rebuilds, precision scraping, and alignment. While mechanical services are provided by partners, MasterControls manages projects to ensure budget and schedule compliance.

Go-to-market motion1 record

Distribution channels1 record

Marketing channels3 records

Core offering

MasterControls is a CNC Systems Integrator that retrofits and rebuilds legacy machine tools by installing modern Fanuc, Siemens, or NUM control platforms. Projects span analog retrofits (reusing existing drives and motors) to fully digital turnkey solutions including electrical schematics, source code development, packaging, configuration, power-up checkout, commissioning, and operator training. Complementary services include PLC upgrades, drive replacements, hydraulic solutions with Delta Computer Systems controllers, and mechanical rebuild coordination through trusted partner rebuilders, delivered onsite throughout the continental United States.

Product overview

MasterControls is a CNC Systems Integrator offering a portfolio of machine tool retrofit and rebuild solutions. The core offering consists of three main CNC control platform retrofits: Fanuc CNC Retrofits, Siemens CNC Retrofits (including SINUMERIK ONE, 840D sl, 828D, and 808D), and NUM CNC Retrofits (Flexium+ series). These are complemented by add-on services including PLC Upgrades, Drive Replacements, Hydraulic Solutions using Delta Computer Systems Hydraulic Controllers, and Mechanical Rebuilds. The company also offers DIY CNC Retrofit Kits for certain applications. Services are provided throughout the continental United States, having completed over 350 retrofit and rebuild projects since 2003.

Differentiator

Problem solved

Functional benefit

Products and services

• CNC Retrofit Solutions Complete CNC control system retrofits for legacy machine tools, covering engineering, electrical schematic development, source code development, packaging, configuration, power-up checkout, commissioning, and operator training for analog and digital configurations.
• Fanuc CNC Retrofits CNC retrofit solutions using Fanuc Series 0/0i control systems with 52-year MTBF, embedded Ethernet, dual check safety, Windows-compatible connectivity, and support for Ethernet/IP, FTP, DeviceNet, and Profibus integration.
• Siemens CNC Retrofits Retrofit solutions using Siemens SINUMERIK controls including SINUMERIK ONE (digital twin), 840D sl (5-axis high-speed), 828D (knee mills to VTLs with ShopMill/ShopTurn conversational programming), and 808D (low-cost control for small machines).
• NUM CNC Retrofits High-end CNC retrofits using NUM Flexium+ 8 and Flexium+ 68 platforms with capability for over 200 axes, 40+ channels, 4000 IOs, more than 1 GB of PLC memory, and 30+ MB of user memory.
• PLC Upgrades Upgrade services that replace relay-based or outdated PLC machines with modern controls to enhance uptime, ease of use, and eliminate failures from obsolete electrical components.
• Drive Replacements Cost-effective AC and DC motor drive replacement solutions allowing customers to upgrade old drive systems without full replacement, including supply of new motors when needed.
• Hydraulic Solutions Cost-effective hydraulic solutions using Delta Computer Systems Hydraulic Controllers for precise control of hydraulically operated axes, providing an efficient alternative to expensive system replacement.
• Mechanical Rebuilds Mechanical rebuilds, field services, precision scraping, and alignment & installation coordinated through trusted machine tool rebuilder partners to ensure projects stay on schedule and within budget.
• DIY CNC Retrofit Kits Do-it-yourself CNC retrofit kits available, particularly Siemens 828D solutions for knee mills, bed mills, and small VMCs, allowing capable customers to perform their own installation.

Quantifiable outcome

• 350+ CNC retrofit and rebuild projects completed since 2003
• +3 more outcomes

Named customers6 records

Segments2 records

Ideal customer profiles1 record

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Integration2 records

Feature6 records

Partnerships

Six partnerships are on record, tiered core and minor.

• NUMcoreTechnology or IntegrationNUM is a key CNC control platform partner. MasterControls uses NUM Flexium+ 8 and Flexium+ 68 CNC platforms for high-end applications, offering scalability from small to demanding configurations supporting up to 200 axes, 40+ channels, and 4000 IOs.
• SiemenscoreTechnology or IntegrationSiemens SINUMERIK control systems are a core platform offering. MasterControls provides retrofits using SINUMERIK ONE, 840D sl, 828D, and 808D controls across various machine types from grinders to 5-axis machining centers.
• FanuccoreTechnology or IntegrationFanuc Series 0/0i CNC systems are offered for retrofits. MasterControls highlights Fanuc's 52-year MTBF, over 700,000 installations, and 200+ high-value features as key benefits for customers.
• Line MachineminorImplementation/ SI/ Consulting PartnerCanadian machine tool rebuild company hired by end customers for mechanical and electrical rebuild work. Line Machine partnered with MasterControls for control upgrades on projects like the Forest Line F200 Horizontal Boring Mill.
• Industrial Machine TechminorImplementation/ SI/ Consulting PartnerPartner machine rebuilder located in Niles, MI that performs mechanical work (headstock rebuild, spindle motor, hydraulic pump, ball screw replacement) while MasterControls handles CNC retrofit.
• Machine Tool Rebuilder NetworkminorImplementation/ SI/ Consulting PartnerMasterControls has built strong partnerships with reputable machine tool rebuilders over the years to address mechanical needs. They refer customers for field services, precision scraping, and installation while managing overall project coordination.

Scale indicators4 records

Recent moves6 records

Expansion highlights5 records

Broad incumbents

• DMG Mori USA: Global CNC machine tool OEM offering advanced 5-axis machining centers and digital manufacturing solutions. Represents the new-equipment alternative to MasterControls' retrofit services.
• Haas Automation: Largest U.S.-based CNC machine tool OEM producing new vertical machining centers and lathes. Competes with MasterControls indirectly because new Haas machines are an alternative to retrofitting legacy equipment.
• Rockwell Automation: Large industrial automation and control systems provider offering PLCs, drives, and motion control products that intersect with MasterControls' PLC upgrade and drive replacement services.
• Siemens Industry (Motion Control / SINUMERIK): OEM of SINUMERIK CNC control platforms sold through integrators like MasterControls. Competes indirectly as end users can buy directly or via other integrators for retrofit projects.

Direct peers

• Ellison Technologies: Major U.S. CNC machine tool distributor and systems integrator offering machine sales, service, and retrofit/upgrades across multiple control platforms. Directly comparable to MasterControls as a multi-OEM CNC systems integrator with full service capabilities.
• Mid-State Machine Products: CNC retrofit and machine tool rebuilding specialist providing control system upgrades (Fanuc, Siemens) and mechanical rebuilds. Closely comparable to MasterControls as a multi-platform retrofit integrator.
• Gosiger Automation: Large CNC machine tool distributor and systems integrator providing CNC retrofitting, automation, and integration services across U.S. industrial markets. Overlaps with MasterControls in CNC retrofit and integration work.
• CNC Design, Inc. Specialized CNC retrofit and machine tool rebuilding firm offering control upgrades, mechanical rebuilds, and motion control services. Directly competes with MasterControls in the retrofit niche across multiple CNC control platforms.
• Rambaugh & Associates: Specialized CNC retrofit and machine tool rebuilding firm providing control system modernization. Direct competitor in the legacy CNC retrofit niche with project-based engineering services comparable to MasterControls.

Regional players

• Industrial Tooling & Supply: Regional CNC machine tool distributor and services provider focusing on its geographic market. Comparable to MasterControls in offering CNC integration and retrofits, but operating primarily in a regional footprint.

Market position

Strengths4 records

Weaknesses4 records

Competitive moat4 records

Key highlights7 records

Customer concentration

Revenue estimate

Valuation estimate

Number of profiles

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about MasterControls