Ease of use for CAM models and powerful CAD functions

6 May 2025

OPEN MIND has introduced the 2025 release of its hyperMILL® CAD/CAM suite. The new version's highlight is the easy-to-use, automatic deburring function. The 2025 release also includes a new tessellation algorithm and a simplified element display for CAD models, which helps further accelerate the CAD part of the software.

Deburred edges and holes are crucial from a functional perspective and significantly enhance the quality and value of the end product. hyperMILL® 2025 offers a package with three new strategies for deburring directly on the machine. Users can deburr a wide variety of component geometries quickly and reliably. The 5-axis deburring function is an effective solution for removing sharp edges from a component. Once the edges have been selected, the strategy automatically calculates all toolpaths.

The strategy incorporates both a 3-axis and a 5-axis mode, in which machining is indexed wherever possible. The same applies to the deburring strategy for edges on holes and intersecting holes. Another approach in this context is hole brushing, which uses a special brushing tool to deburr cross holes, threads, or other features, or to enhance surface quality. The machining process is divided into several phases, with machining parameters such as spindle, feed rate, speed, coolant, and dwell time defined for each phase.

5-axis automatic mode
The new 5-axis algorithm in hyperMILL® calculates an optimal machining sequence for simultaneous and indexed tool movements, thanks to the pre-analysis of the entire toolpath. Both indexed and simultaneous processing phases are selected automatically, with the indexed method preferred for its faster operation. The new 5-axis ISO Machining strategy enables machining of surfaces according to the alignment of the ISO lines (U and V). Additionally, a high-precision surface mode with a uniform point distribution is available, along with feed adjustments for curvatures and 3D radius correction. This feature is also applicable in 5-axis profile finishing for both surface and cavity machining. Both strategies build on proven 3D techniques.

Milling and turning
The pocket milling algorithm has been redeveloped for 3D-optimised roughing to achieve greater efficiency during the roughing process, especially when machining large lateral infeeds. You can better control toolpath rounding by defining the contour radius and path radius separately. This is important for the new ‘Axis Parallel mode’ machining strategy when working on flat surfaces. Additionally, there are new functions for turning. Using the 3D model to create a V-sketch for quickly and easily defining turning contours is now possible. You can utilise the V-sketch to specify dimensions and tolerances. Based on these values, the turning contour can be re-positioned at the tolerance centre.

The new automatic stock chain enhances security, particularly during transitions between turning and milling operations or other projects with numerous process steps. hyperMILL® automatically generates all stock in the correct sequence in the background, even if the job order has been modified.

hyperMILL® VIRTUAL Machining
Lathes with a turret and a main spindle are mapped as a digital twin for hyperMILL® VIRTUAL Machining. Turning in hyperMILL® now supports FANUC, Mitsubishi, and Siemens controls. Another new feature is job calculation with the virtual machine. This means that the machine model is available to hyperMILL® during toolpath calculation. Collision control and avoidance are carried out, taking machine geometry and limits into account. It results in more precise, optimised toolpaths, especially in tight spaces.
hyperMILL® and Hummingbird-MES: Improved tool management
The integration between hyperMILL® and Hummingbird-MES is also progressing, particularly in tool management.

The release of the new version enables users to benefit from an even deeper integration of both systems. Tool data from the hyperMILL® tool database can now be managed consistently and conveniently across systems. Tools can be exported directly from hyperMILL®, including all relevant technology parameters. These tools are automatically locked in hyperMILL® as soon as they are transferred to Hummingbird to avoid inconsistent tool data. This establishes a consistent, reliable, and efficient process for tool management – from the CAM system to Hummingbird and other systems such as a tool pre-setter.