Improved performance and process reliability Open Mind releases Hypermill 2026

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Software company Open Mind Technologies has released version 2026 of its cad/cam suite Hypermill. The new version is designed to increase both the speed at which NC programs can be created and process reliability.

For the first time, the software and its NC code-based simulation in Hypermill virtual machining support additional tool types and angle heads. Version 2026 enables angle heads to be integrated directly into Hypermill cam programming. The angle head is defined as part of the nc tool and configured via the Hypermill tool builder.

The virtual machine takes angle heads into account throughout NC code generation, toolpath optimization, simulation and collision checking. Critical phases such as angle head approach and retraction are also simulated. The Hypermill virtual machining optimizer automatically optimizes toolpaths for angle head machining. In addition, approaching via a curve enables safe access to hard-to-reach areas of the component. The function is initially available for Siemens Sinumerik 840d and Heidenhain controls.

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2D hale machining for sealing surfaces

Hypermill 2026 also supports 2D hale machining, also known as contour planing, both in machining strategies and in simulation. The process is designed to produce scratch-free surface finishes, as required for sealing surfaces in battery manufacturing, the semiconductor industry and mold and die making.

As a trailing axis, the spindle axis functions ensure that the tool is continuously guided perpendicular to the contour.

More reliable 3D and 5-axis rest machining

Rest material machining has been further automated in Hypermill 2026. The calculation algorithms for the z-level, parallel and normal machining strategies have been redesigned to make the processing of rest material areas more reliable and efficient.

According to Open Mind, rest material areas can now be detected more precisely and machined more reliably. Feed specifications are taken into account, resulting in more uniform toolpaths. The system also automatically integrates a smooth overlap in steep, flat and transitional areas during entry and exit movements.

This automation applies to both 3D and 5-axis machining. In 5-axis machining, users can specify a minimum distance between the tool shank and the part using the new minimum clearance angle option. This ensures that machining is performed with a defined clearance angle.

Turning with Hypermill

With CAM plan turning, Hypermill provides end-to-end programming support for turned and mill-turned parts. In many cases, turning programming only includes geometries without tolerances, fits or manufacturing information. Until now, this data had to be added manually, which was time-consuming and prone to errors.

CAM plan turning enables turning contours to be enriched quickly and consistently with relevant manufacturing information. This is intended to reduce programming time and increase process reliability for turned and mill-turned parts.

The Hypermill turning solutions have also been expanded to include new complex turret-type machine configurations for improved collision checking.

Optimized control of eroding paths

In the Hypermill electrode module, the control of eroding paths has been improved. The changes allow more flexible use of feed and rapid movements, helping to optimize eroding paths and reduce machining times.

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