Hypermill Suite: Bridging Additive and Subtractive Manufacturing at Formnext

Open Mind at Formnext Additive manufacturing and finishing with Hypermill

2025-09-17 Source: Open Mind 1 min Reading Time

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At Formnext, Open Mind will showcase how its Hypermill suite bridges additive and subtractive manufacturing. With integrated 5-axis strategies, simulation technologies, and the new Best Fit feature, the software ensures precise finishing of additively manufactured parts and maximizes process reliability.

The size of the head compared to the workpiece highlights the importance of simulation for collision avoidance.(Source: Open Mind) — The size of the head compared to the workpiece highlights the importance of simulation for collision avoidance.
(Source: Open Mind)

Software company Open Mind Technologies will be exhibiting at formnext from November 18 to 21, 2025. At Messe Frankfurt, Hall 12.0, Booth B99, Open Mind will present CAD/CAM functions for both additive manufacturing and the precise finishing of additively manufactured parts. Hypermill Additive Manufacturing extends the possibilities of 5-axis simultaneous machining for the Direct Energy Deposition (DED) process and Wire Arc Additive Manufacturing (WAAM).

The 3D printing module in Hypermill Additive Manufacturing is fully integrated. This advantage becomes particularly clear when seamlessly switching between additive and subtractive machining on hybrid machines. The additive functions of the CAD/CAM suite benefit from Opem Mind’s 5-axis and simulation technologies, ensuring maximum process reliability.

Apart from the special case of hybrid machines, where additive and subtractive manufacturing are performed consecutively, postprocessing requires the setting-up of a raw part with small allowances in the machine tool. In Hypermill’s virtual machine, the company has introduced Best Fit, an innovative alternative to manual alignment of workpieces for further machining. The prerequisite is a 5-axis machining center with a digital probe. The misaligned raw part billet is probed directly on the machine, and the measurement protocol is transferred to the CAM system. The software adapts the NC code to the real part position. This way, the virtual programming environment is aligned with the actual clamping situation.

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