OPEN MIND Technologies enhances hyperMILL 2025 with advanced additive manufacturing features for optimized hybrid manufacturing workflows.
German software developer OPEN MIND Technologies is pushing deeper into the additive manufacturing space with significant enhancements to its flagship hyperMILL CAD CAM software. The new version features a variety of smarter workflows that combine both additive and subtractive manufacturing processes, which could alter the way manufacturers design and produce complex parts.
The hyperMILL 2025 CAD/CAM Software Suite, already a staple in workshops handling everything from basic 2.5D to complex five-axis machining, now features a specialized “Linking Job” capability within its Additive Manufacturing module. This innovation automatically determines the optimal tool orientation based on part geometry and selects the most efficient tool path – either indexed or simultaneous – saving valuable production time.
“Depending on the 3D printing process and component, hyperMill will select the appropriate subtractive tool path,” explains a company spokesperson. “In general, the aspiration is that more precise and time-consuming pathing is employed where it is necessary, and time is saved on parts of a part that can be done more cheaply.”
But the advancements don’t stop there. The 2025 release also introduces an intelligent deburring strategy that automatically identifies holes and generates appropriate tool paths for edge finishing, with both 3-axis and 5-axis options available. For manufacturers dealing with precision parts, this automation eliminates time-consuming manual programming steps.
The pocket milling algorithm has also received a complete overhaul, specifically optimized for high-feed cutters in 3D operations. Engineers can now achieve greater efficiency during roughing while maintaining better machining control – particularly valuable when handling large lateral in-feeds and working with remaining material. Additional customization options include defining contour and path radii for improved toolpath rounding.
Another practical enhancement is the Dynamic Stock counter, which now tracks material stock across all machine jobs, including those resulting from linking operations. This comprehensive view helps operators better manage material usage and production scheduling.
The update also adds enhancements to spindle functionality for the Fanuc, Siemens and Mazak controls, the three most widely used control types in the industry.
These developments arrive at a crucial moment in manufacturing technology. As cell-based manufacturing solutions gain traction, combining additive and subtractive processes becomes increasingly important. Marine construction The aerospace, defense and energy sectors are all heavily investing in hybrid manufacturing techniques.
“There is a collision course in the making between the 3D printing software market, efficient additive and subtractive cell-based manufacturing, and the CAD CAM market,” notes an industry analyst watching these developments.
OPEN MIND Technologies isn’t alone in this space. Companies like AiBuild and Adaxis are extending their capabilities, while Autodesk Fusion aims to consolidate much of this functionality into a single platform. The competition is heating up as manufacturers increasingly demand integrated solutions that bridge traditional machining with additive technologies.
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For hyperMILL users, these enhancements translate to more streamlined workflows and expanded capabilities for hybrid manufacturing projects. As adoption of combined additive-subtractive approaches continues to grow, particularly in sectors like vehicle armor, boat building, and turbine component repair, the strategic importance of such versatile software tools only increases.
With tens of thousands of components already being repaired through hybrid manufacturing approaches, the market for capable CAD CAM solutions with strong additive capabilities appears poised for significant growth.
