Formnext 2026 Open Mind links metal deposition and finish machining

From November 17–20, 2026, at Formnext, Open Mind will demonstrate how the Hypermill CAD/CAM system supports additive manufacturing and subtractive post-processing of parts. Intelligent, end-to-end processes are not limited to hybrid machines. The Best Fit function eliminates sources of error when switching between machines.

Whether using Direct Energy Deposition (DED) or Wire Arc Additive Manufacturing (WAAM), fully exploiting the potential of additive manufacturing often requires programming highly complex 5-axis simultaneous machining operations. DED additive manufacturing toolpath planning differs from the subtractive one in the sense that the first focuses on keeping a constant velocity to achieve a uniform material deposition, while the second on respecting precise position and orientation. With Hypermill Addtitive Manufacturing, NC codes for metal deposition can be programmed with ease. In Hypermill Virtual Machining, the simulation of machine movements for collision avoidance is based on the NC code and the machine’s digital twin. The Additive Manufacturing module is fully integrated into Hypermill and serves as a comprehensive software solution for efficient hybrid machining that combines additive and subtractive processes on a single machine.

While hybrid machines offer advantages in maintenance, prototyping, and small-batch production, a process chain involving multiple machines can be more cost-effective for larger production runs. Until now, one of the major challenges in post-processing 3D printed parts has been aligning the blank in the machine tool. Since high-precision machining is performed on 3D-printed parts that are already close to their final dimensions, Open Mind offers Best Fit, an automated solution for precise workpiece alignment. Best Fit replaces the costly and error-prone manual workpiece alignment process by adapting the NC code and machine simulation to the actual position and orientation of the part.

“From conformal cooling channels in mold manufacturing to innovative material combinations and customized medical implants, all the way up to lightweight structural components for the aerospace industry: Formnext exhibitors and visitors are well aware of the potential of the additive and hybrid technology. And in fact, many well-known companies in these industries are already using Hypermill’s additive manufacturing capabilities,” says David Bourdages, Product Manager for Additive Manufacturing at Open Mind Technologies.

“As additive manufacturing becomes increasingly established, it is equally important to create a robust, integrated virtual environment that supports all phases of production. This is where software plays a key role, and Hypermill is perfectly suited to meet these requirements. We offer seamless process chains covering the entire production process, from CAD to CAM programming for additive and subtractive manufacturing to NC-code-based simulation using a digital twin, the integration of CAD/CAM software and machines with Hypermill Connected Machining, and finally production planning and control with Hummingbird-MES.”

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