From hybrid machine tools to AI-driven robotics and automated post-processing, additive manufacturing is entering a new phase of industrial maturity. A look at current technologies shows how AM is becoming a reliable, scalable element of modern production.

Software company Open Mind launched the 2025 release of its Hypermill CAD/CAM suite. The highlight of the new version is the easy-to-use, automatic deburring function. The 2025 release includes a new tessellation algorithm and a simplified element display for CAD models, which help further accelerate the CAD part of the software.

With the Vision Laser, Walter introduces a high-performance alternative to wire erosion — offering faster processing, finer surfaces, and greater flexibility for complex tool geometries.

For greater process reliability and a wider process window in injection moulding, as well as significantly longer maintenance intervals, Dressel + Höfner Automotive now relies on DLC-coated ejector pins for venting from standard parts manufacturer Knarr as a matter of course in its injection moulding tools.

BMW is expanding its use of 3D printing in production, deploying lightweight, custom robot grippers and sand casting moulds to boost efficiency, cut emissions, and enable more flexible, automated manufacturing across its global plants.

Packaging manufacturer Alpla Group is strengthening Alplainject, its injection-moulding division, with the acquisition of KM Packaging. This acquisition means the international plastic packaging specialist will now also manufacture high-quality closures for tubes, bottles and jars, including in clean rooms if desired, at six additional sites in Germany, Austria, Poland and the US.

Manufacturers seeking greater flexibility and durability in milling now have a solution: Seco’s revamped Round 20 series offers optimized insert usage and rugged reliability.

Fotec Research and Technology Transfer at the University of Applied Sciences Wiener Neustadt has succeeded in making the reworking of additively manufactured components more economical with the help of a process known as ‘Hirtising’.

Fakuma 2026 is shaping up to be a highlight for the plastics processing industry: With two-thirds of exhibition space already booked, the 30th edition of the international trade fair in Friedrichshafen promises strong participation, global relevance, and a diverse supporting programme.

Simulation in CAM has evolved from a visual aid to a core pillar of safe, efficient manufacturing. This personal deep dive traces its transformation — from the early days of 5-axis backplotting to today’s real-time collision avoidance and GPU-accelerated material removal. What has been achieved, what challenges remain, and what lies ahead?