The Carmelite Brothers of Wyoming are undertaking a remarkable project: designing and building their own Gothic-style monastery using modern machining tools. Facing limited funds and no formal training in engineering or fabrication, the monastic community turned to digital design and CNC machining to bring ornate stonework and architectural details to life. Their journey shows how traditional craftsmanship and cutting-edge technology can merge in a deeply purposeful project, tells Machine Design.
The project began in 2003, and the Brothers purchased their current monastery site in Meeteetse, Wyoming, in 2010. With private donations and their own labor, including roasting and selling Mystic Monk Coffee, they’ve completed most of the complex’s structures, leaving the intricate chapel as their main ongoing challenge. To tackle detailed stone carving and architectural components, the Brothers taught themselves CAD and CAM software, including Rhinoceros 3D for design and, more recently, Mastercam for sophisticated toolpathing and multi-axis machining.
Mastercam’s robust features, including multi-axis toolpathing and collision detection, have been crucial in turning detailed designs, from foliated canopies to carved gargoyles, into precise machined parts. The monastery team worked with a local Mastercam reseller for hands-on guidance and leveraged online tutorials, community forums, and resources to climb the steep learning curve. Over time, they’ve reduced programming time dramatically and expanded their ability to machine complex geometries with minimal manual finishing.
Their machining toolkit now includes seven CNC machines, such as a 5-axis gantry mill, enabling deep undercuts and smooth surface finishes that would be extremely time-consuming by hand. Tools like symmetry mirroring in Mastercam help them quickly replicate detailed elements, saving countless hours.
The Brothers’ unconventional workshop, set against Wyoming’s mountains, underscores a larger point: with dedication and modern tools, remarkable craftsmanship doesn’t need to wait for external contractors. By combining spiritual purpose with technical skill, they’re transforming stone into both architectural form and a testament to creative problem-solving.