Directed Energy Deposition

The Best of Both Worlds: Additive and Subtractive Manufacturing with hyperMILL ADDITIVE Manufacturing

ded pin

hyperMILL is a powerful solution for combining standard and generative machining in a single, hybrid manufacturing process. It features unique 5-axis technology from OPEN MIND that is ideal for simultaneously controlling 5-axis material deposition and thereby achieving optimal results.

hyperMILL ADDITIVE Manufacturing provides a flexible strategy for direct material deposition. The Directed Energy Deposition (DED) process involves directly, selectively applying material to a component or platform. Both laser-based powder nozzle machining heads and wire arc additive manufacturing (WAAM) can be controlled during this process.

When additive and subtractive manufacturing are combined in a single machine tool, this is referred to as a hybrid manufacturing process. hyperMILL enables users to perfectly program the cladding and the milling together. True-to-detail application and removal simulation as well as stock tracking between the individual machining steps guarantee the greatest possible process reliability.

  • Flexible strategy for additive material application
  • Variable filling strategies for planes as well as free-form shapes
  • 5-axis simultaneous application with optimal tilt strategies
  • Full simulation of additive and subtractive processes, including material deposition
  • CAD interface to all common CAD systems
  • High level of laser configurability via technology parameters in the tool database
  • Hybrid stock tracking for all processes
Hybrid process blade repair

hybrid process blade repair 

Additive process additional material application

ded 3d material add 

Additive process part build

additive process part build

The high deposition rates of the direct material application, combined with modern machining centers, enable a wide range of applications. Hybrid manufacturing is perfect for carrying out local, limited repairs on worn or damaged areas such as tooling or stamping die components or turbine blades and this within a short period of time. Moreover, composite metal structures can be manufacture by welding various materials or via heat treatment with a laser. This new technology is highly significant, particularly in the field of tool and mold making as well as in the aerospace industry.

hyperMILL by OPEN MIND offers the perfect solution for securely, continuously controlling all processes, from additive material application through to machining.


Having a continuous process chain from material application to material removal is particularly decisive for hybrid systems. During the simulation, the material application is mapped and simultaneously created across the entire simulation process. The major advantage is that milling can then be carried out directly on the application stock. Meanwhile, additive and subtractive processes can be combined as desired and securely reviewed in the simulation.

ded simulation detail

Stock tracking

hyperMILL calculates the corresponding stock for each additive or subtractive process and adds this to a stock chain. This stock is not only used for simulation purposes, but also for collision checks. This results in secure, precise mapping of the machining process.


Every technology manufacturer uses their own values and parameters for controlling the application. hyperMILL provides a flexible solution that can be used to control individual parameters. Technology parameters can be defined and stored in the tool database. During the postprocessor run, the corresponding NC code is then created together with all control commands for the respective machine.

What’s new in hyperMILL 2020.1

hyperMILL 2020.1 offers many innovations in all areas. General improvements in the new version increase usability and the performance of programming.

Efficient processing of rest material in corners is ensured by the new 3D and 5-Axis Corner Rest Machining. With the hyperMILL AUTOMATION Center users can realize small automation tasks themselves. A new strategy for the machining of turbine blades with conical barrel cutters increases efficency significantly.


whats new hypermill 2019 2pdfDownload a hyperMILL Version 2020.1 brochure2.18 MB

What's new in hyperMill 2020.1?





Split Job

toolpath split after time

hyperMILL now makes it possible to automatically split toolpaths according to a range of criteria. This makes it possible to easily change tools after a defined period of time or toolpath length, for example. Particularly in the case of materials that are difficult to machine, this provides optimal control over the tool life, making it possible to change inserts or switch in a sister tool, for example.
This function makes it unnecessary to manually edit the toolpath. Repeatability is guaranteed, even if the initial job is changed.
This function is available in all 3D and 5-axis cavity strategies.

Benefit: Increased process reliability.

Slot-Rib Probing

probing slot ridge

A new strategy makes it possible to measure slots and ribs using the familiar technology parameters. The area to be measured is defined by a simple contour selection. The strategy automatically determines the optimal measuring point.

Benefit: Improved probing functions.

3D Optimized Roughing

3d 5 axis corner rest machining

High-performance mode* is now also available in this strategy. The strategy also offers improved area sorting, resulting in fewer retractions. Areas in which a collision occurs are specifically excluded. In doing so, the collision check considers the tool including the shaft, extensions, and tool holder.

Benefit: HPC roughing is supported.

*High-performance mode supports the familiar hyperMILL MAXX Machining technology for roughing. This generates spiral and trochoidal toolpaths and optimizes machining. High-performance cutting (HPC) is characterized by a very high stock removal rate.

3D Profile Finishing

3d profile finishing surface extension

Two new functions are available:

Automatic face extension
During programming, the ‘Automatic face extension’ function can be used to extend the circumference of selected milling surfaces. This CAD-for-CAM function eliminates the need to modify the milling faces in the CAD system beforehand.

Free tool geometry
Free tool geometry can now be used in 3D profile finishing. This makes it possible to use any tool types, such as high-feed cutters for example, for highly detailed programming and collision control.

Benefit: Increased user-friendliness, use of free tool geometries.

3D- and 5-axis Corner Rest Machining

3d 5 axis corner rest machining

This strategy merges optimized toolpaths for high-performance rest material removal in corners. Parallel and Z-level toolpaths ensure efficient rest machining. Optimized machining of floor areas is also possible. This means that the best method is applied in every situation.

5-axis Corner Rest Machining makes indexed machining of difficult to reach corners possible. Automatic inclination selection, simultaneous linking movements, and collision avoidance are available in this process.

Benefit: Efficient rest material machining.

Additive Manufacturing – It’s Only Truly Perfect with CAD/CAM

additive isogrid full prototype

hyperMILL ADDITIVE Manufacturing is a powerful solution for additive manufacturing and helps to take full advantage of this new and growing technology. It allows you to perfectly and flexibly control additive processes, and on many machines to control both additive and subtractive processes. Two methods have become established in the field of additive manufacturing – for Powder Bed Fusion (PBF) OPEN MIND is the ideal solution provider with its CAD/CAM software which optimally integrates into the process chain to post-process printed parts. hyperMILL® ADDITIVE Manufacturing actively controls the material application of the Directed Energy Deposition (DED) process and thereby ensures optimal results.


  • Flexible strategy for additive material application
  • Various filling strategies for planes as well as free-form shapes
  • Filling strategies for 2D and 3D sections
  • 5-axis simultaneous application with optimal tilt strategies
  • Full simulation of additive and subtractive processes, including material deposition
  • One postprocessor for milling and/or additive processes
  • CAD interface to all common CAD systems
  • High level of laser configurability via technology parameters in the tool database
5-axis Blade Tangent Milling

5 axis blade tangent milling

This new strategy facilitates top milling of turbine blades using conical barrel cutters with a large conical angle. As a result, higher feedrates remain possible, while avoiding center-cutting. Large step-overs are possible with the conical barrel cutter and provide a fine surface finish.

Benefit: Increased efficiency, improved surface quality.

Automatic Contour Feature Splitting

3d 5 axis corner rest machining

hyperMILL jobs automatically determine the area to be machined based on the turning contour. The grooving job will automatically recognize if a contour is a groove, for example. This makes it faster and easier for the user to program certain areas.

Benefit: Simplified programming.


automation center en

The new hyperMILL 2020.1 version allows users to automate joblist creation processes using the hyperMILL AUTOMATION Center.

The hyperMILL AUTOMATION Center is the foundation for further automation, and serves as both a development and runtime environment. This makes it possible to standardize and automate complex process workflows in hyperCAD-S and hyperMILL. The hyperMILL AUTOMATION Center provides the toolkit for OPEN MIND’s internal experts to provide comprehensive process automation, and is also available for end-users in a basic version.

The first expansion is included in hyperMILL by default.* This allows you to automate the joblist creation process and the selection and positioning of the clamping device, as well as define a uniform process for all programmers. Users are also able to use standardized clamping devices during programming.

*Only available for hyperMILL in hyperCAD-S.


  • Comprehensive template functions
  • Individually configurable
  • Extended stock model options
  • Clamping device management
  • Documentation options for individual processes
hyperMILL VIRTUAL Machining Optimizer

virtual machining optimizer linking

The Optimizer offers improved performance for automatic solution selection and the calculation time during the postprocessor run. In addition, settings for the preferred direction control and collision avoidance may be defined in each individual hyperMILL job. This makes it possible to override the global settings in the machine definition.

The new ‘Smooth linking’ function automatically optimizes all linking movements between the individual operations during the postprocessor run. This ensures that repositioning and movement is always in close proximity to the workpiece and checked for collisions. Thanks to this function, programming using job linking is not necessary in hyperMILL.

Benefit: Significant reduction in auxiliary processing times.

What’s new in hyperMILL 2019.2

hyperMILL 2019.2 offers many innovations in all areas.

These new features include increased surface precision during milling and improved turning strategies. A new model for 5-axis Tangent Machining enables a perfect milling result across multiple surfaces with different ISO orientations. The tool life monitoring in High Performance Turning guarantees a secure turning process.


whats new hypermill 2019 2pdfDownload a hyperMILL Version 2019.2 brochure3.48 MB

What's new in hyperMill 2019.2?





Changing the job list name and comments

Thanks to an improvement made to the job list management, it is now possible to modify the job list name and comments without having to subsequently recalculate the project. The new or modi-fied comments are used and output directly in the NC file or in the report.

Benefits: reduced programming time.

3D Shape Z-level Finishing

hypermill 2019 2 3d shape z level finishing

Two new functions facilitate optimized machining:

  • The ‘High precision surface mode’ option ensures ultra-smooth surfaces with tolerance in the µm range.
  • The toolpaths are trimmed automatically in undercut situations in surface mode with extended milling surfaces. When surfaces without extensions or bounding curves are used, the toolpath trim function can be activated manually.

Benefits: More efficient machining, better surface quality.

5-axis Tangent Machining

hypermill 2019 2 5 axis tangent machining

The hyperCAD-S ‘Global fitting’ function has been integrated directly into the CAM strategy. In ‘Global drive shape’ mode, a surface with defined ISO orientation is automatically generated and used for the toolpath calculation when multiple milling sur-faces are selected. The orientation in U and V can also be defined here. The ‘Offset curve’ option is also available to allow toolpath guidance along a curve. Optical feedback, which includes the tool, global surface, and infeeds, makes this strategy even more user-friendly.

Benefits: Simplified programming.

High Performance Turning

hypermill 2019 2 high performance turning

Tool life monitoring has been added to High Performance Turning. Machining is interrupted after a certain distance has been covered, after a specific time, or after a specified number of tool-paths. If the defined limit is reached, a retract macro is generated automatically and the job ends.

Benefits: Increased process reliability, simplified use of sister tools.

What’s new in hyperMILL 2019.1

hyperMILL 2019.1 stands for even more performance and better milling results!

A highlight is the ‘5-Axis Prismatic Fillet Finishing’, an innovative method to make finishing with barrel cutters efficient. These additions complement the hyperMILL® MAXX Machining performance package. Furthermore, the ‘Surface precision mode’ means better surfaces can be achieved in ‘3D Profile Finishing’ than ever before.


whats new hypermill 2019 1 en bropdfDownload a hyperMILL Version 2019.1 brochure4.00 MB

What's new in hyperMill 2019.1?





Changing the job ID

job id en

An improvement in job management now means a job ID can be changed without having to subsequently recalculate the machining job in question. The consecutive numbering of the compound and machining jobs is controlled via a start value and an increment value.
Benefit: Transparent structuring, reduced calculation times.

Thread Milling

thread milling

The new strategy for Thread Milling makes programming simpler thanks to a range of improvements:

  • New user-friendly interface
  • Improved roughing mode with different roughing options
  • Edge control
  • Simple control of left- and right-hand threads
  • Automatic approach and retract macros

Benefit: Simpler programming.

5-axis Prismatic Fillet Finishing

5 axis prismatic fillet finishing

The new strategy enables barrel cutters to be used highly efficiently in the finishing of prismatic fillets. An extremely high feedrate is achieved with plunging and pulling motions. The conical barrel cutter is used according to the principle of high feedrate cutters in this strategy. The calculation of the tilt and the contact point of the barrel cutter are fully automated. This allows, for example, high-quality transitions between different wall areas to be formed. Ball and bullnose end mills can also be used efficiently with this strategy.
Benefit: Easy to use, faster machining.

3D Profile Finishing

3d profile finishing

The ‘Surface precision mode’ option is available to further improve surface quality during Profile Finishing. Toolpaths are calculated using actual component surfaces and not a faceted calculation model. This allows ultra-smooth surfaces to be produced.
Benefit: Improved surface quality, less rework machining.

What’s new in hyperMILL 2018.2?

Quicker programming, more efficient machining – hyperMILL 2018.2 has a lot to offer! Users will enjoy a large number of innovations and optimizations.

Practical CAD-for-CAM functions such as automatic face extension for 3D Z-level Shape Finishing reduce the amount of programming required and ensure improved milling results. There are also two new strategies available for measurement.


whats new hypermill 2018 2 brochurepdfDownload a hyperMILL Version 2018.2 brochure3.63 MB

What's new in hyperMILL 2018.2?






3D Z-level Shape Finishing

3D shape level surface extention barrel

Two new functions are available for 3D Z-level Shape Finishing:

Automatic Face Extension

During programming, the ‘Automatic face extension’* function can be used to extend the selected milling surfaces. This CAD-for-CAM function eliminates the need to modify the milling faces in the CAD system beforehand.

New Tool Types

Barrel cutters can now be used for 3D Z-level Shape Finishing, and are launched in the strategy as a standard tool. General, tangential, and conical barrel cutters are supported.

Benefit: Reduced programming time, improved milling results.

CAD integrations for the hyperMILL CAM software

hyperMILL is always used in combination with a powerful CAD system. Depending on customer requirements, this could be hyperCAD-S, SOLIDWORKS, or Autodesk Inventor. The CAD integrations from OPEN MIND allow CNC programs to be created directly in the CAD software.

What are the advantages of CAM software that is integrated in a CAD system? CAM programmers are able to work in a familiar software environment. Continuous workflows help to avoid errors. At the same time, training costs are reduced as users do not have to find their way around a completely new user interface. The period of training is significantly shorter and NC programmers can work productively much more quickly. In general, the work load of the CAM user is reduced as NC machining requires no complex import, export or translation of model files. As a result, there is also less data to manage.

The full associativity with the CAD model is guaranteed at all times. This means that changes made to the CAD data result in the loss-free, automatic update of the CAD commands and therefore in a direct recalculation of the toolpaths. Joint access to an identical database simplifies and speeds up the processes in the CAD/CAM software. Working with the CAD/CAM system is generally much more efficient.

Integrated CAM software for SOLIDWORKS, Autodesk Inventor, hyperCAD-S

OPEN MIND provides integrated CAM solutions for leading CAD solutions SOLIDWORKS or Autodesk Inventor so that NC programmers can work in a familiar environment. hyperMILL for SOLIDWORKS and hyperMILL for Autodesk Inventor both deliver outstanding performance and allow all users to achieve high-quality results with the respective CAD integration. Full integration, simple operation and fast software processes make manufacturing generally more efficient.

The CAD-integrated hyperMILL CAM software allows construction data to be processed simply and without any problems by the NC programmer. The 64-bit, multi-core technology used in the CAM solutions from OPEN MIND helps ensure that toolpaths for the most complex machining operations can be implemented in the shortest time possible. Powerful NC programs help companies to achieve their goal faster, that is, to further streamline the production of precision parts. This is a key success factor for the entire manufacturing process.

OPEN MIND offers yet another CAD integration: hyperMILL for hyperCAD-S. Commercially available CAD systems are usually specifically designed for the main user group of designers or engineers. CAM programmers work completely differently with CAD software and need other functions that allow them to prepare CAD models in the best possible way for efficient NC programming. With its hyperCAD-S software, the CAM provider, OPEN MIND, has designed and developed its own new CAD software right from scratch that is perfectly designed to fulfil the special requirements placed by CAM programmers on CAD software.

What’s new in hyperMILL 2018.1

hyperMILL 2018.1 offers a number of new functions for more efficient programming and manufacturing.

hyperMILL VIRTUAL Machining is the new NC code-based simulation solution. 3X simultaneous Turning opens up new possibilities for turning.


whats new hypermill 2018 1pdfDownload a hyperMILL Version 2018.1 brochure5.74 MB

What's new in hyperMILL 2018.1?





General | Project assistant

Project assistant UI

The new Project Assistant allows users to define all the settings necessary for a joblist more quickly. Intuitive user guidance and automated functions make it easier to create a joblist.

Benefit: Simple and fast joblist creation.


Smooth overlap

3D smooth overlap

The new ‘Smooth overlap’ function optimizes the surface quality in transition areas during slope-dependent machining. Slope boundaries are more precise, and perfect surface blends are achieved at slope boundaries or rest machining boundaries are improved by lifting the tool slightly.

This function is supported in the following strategies:

  • 3D Profile Finishing
  • 3D Z Level Finishing
  • 3D Complete Finishing
  • 3D Z Level Shape Finishing
  • 3D Automatic Rest Machining
  • 5X Rest Machining

Benefit: Improved surface quality.


3D Optimized Roughing

3D optimized roughing HSC

Two new functions are available for adaptive pocket machining:

  • With the ‘High feed machining’ option, the lateral infeed can be automatically calculated by defining a scallop height. Special movements have been implemented to avoid rest material in corners when there is a very high lateral infeed.
  • Intelligent cut distribution and optimized toolpaths provide greater process safety for remaining rest material.

Benefit: High degree of user-friendliness when using high feed machining with high feed cutter.


3-axis simultaneous Turning

3 axis simultaneous turning

Two new strategies for simultaneous machining* enable even more efficient mill turning. Complex workpiece geometries can be machined in a single job step by simultaneously adapting the approach angle during the turning operation. Here, synchronization lines can be used to set the movement sequence of the pivoting axis. The simultaneous movement of the third axis is calculated automatically between two synchronization lines.

Roughing: The innovative approach, which involves using a simultaneous pivoting axis during rouging, offers the user many benefits. The varying tool orientation ensures that the insert is optimally utilized and also helps to extend the tool life.

Finishing: The simultaneous movement of the pivoting axis allows complex contours to be finished in a single job step. This means tool changes and mismatches can be avoided due to a limitation of the accessibility and visible edges.

Benefit: Improved surfaces, fewer tool changes and extended tool life.

*Note: The 3-axis simultaneous Turning requires an adapted postprocessor.


Highly efficient turning: Turning has never been faster!

Rollfeed turning strategy

Thanks to the innovative rollFEED cutting inserts from Vandurit for lathes and the perfectly adapted hyperMILL rollFEED Turning strategy*, flawless workpiece contours can be achieved in no time at all.

How the process works
This unique turning operation involves rolling the tool insert on a workpiece surface of any shape. The cutting movement is produced by a horizontal swivelling of the pivoting axis with simultaneous compensation for the X and Z axes.

Machining grooves with a single tool
When grooves are machined, the strategy automatically guides the tool from the first to the second plane level via the cylinder face. This way, grooves can be machined with high efficiency with a single tool in a single movement and thanks to the combination of roll and turn movements, even workpieces with large radii can be machined reliably.

*Note: hyperMILL rollFEED Turning requires an adapted postprocessor.


  • Highly efficient process
  • Generates perfectly finished surfaces free of twists
  • Simple to program
  • Fewer tool changes
  • Undercuts can be integrated into rolling movement
  • Mill-turn machines with a pivoting axis only require the rollFEED holder and inserts.
  • Possible to upgrade existing machines with the rollFEED drive unit

hyperMILL VIRTUAL Machining: Perfect fusion of the virtual and real worlds

Virtual Machining Center en

OPEN MIND has developed hyperMILL VIRTUAL Machining* to evaluate, control and optimize machining processes more reliably. This highly efficient simulation solution consists of three modules: Center, Optimizer and CONNECTED Machining.

Increased safety in simulations
Actual machining situations, that is, the machine including controller and PLC, are mapped virtually and simulated based on the NC code in the hyperMILL VIRTUAL Machining Center. All processes are transparent to the user, and can be analyzed in detail. Real-world machine collisions that can cause costly machine damage, production downtime and thereby critical delays, are avoided.

More than just simulation
Powerful optimization algorithms ensure efficient multi-axis machining design. The hyperMILL VIRTUAL Machining Optimizer automatically finds the best tilt angle, thereby ensuring seamless machining. In addition, hyperMILL CONNECTED Machining enables in-depth networking and synchronization with the machine.

Greater efficiency thanks to a new generation of postprocessors
Postprocessor technology* has also been significantly further developed with the hyperMILL VIRTUAL Machining simulation solution, and supplemented with many innovative functionalities. For instance, bidirectional linking is now possible between the NC program and the machining information from hyperMILL. By means of this connection the respective hyperMILL job can be assigned to the NC Code.

*Note: hyperMILL VIRTUAL Machining requires a hyperMILL VIRTUAL Machining postprocessor.

What’s new in hyperMILL 2017.2

Faster, easier and more versatile: hyperMILL 2017.2!

One absolute highlight is the new electrode module that can be used to reliably and efficiently manufacture electrodes. There is also a new feature type to quickly detect T-slots in T-slot milling. Meanwhile, an expansion to the 3D-optimised roughing ensures a significant increase in efficiency. And finally, during 5-axis swarf cutting with one curve, it is now easier for hyperMILL for SOLIDWORKS users to create programs for swarf cutting operations.


whats new hypermill 2017 2 en bropdfDownload a hyperMILL Version 2017.2 brochure3.82 MB

What’s new in hyperMILL 2017.2






General | T-slot feature and feature recognition

2 5D T Slot Feature Recognition

The new feature type allows T-slots to be quickly and easily recognised in the component. Two types are available for feature recognition: ‘T-slots’ and ‘Pockets with bottom and T-slots’. This feature information is incorporated into the ‘T-slot milling on 3D model’ strategy so that slots can be manufactured in a highly efficient way with just a few clicks.

Benefit: Simple and fast T-slot recognition and programming.

CAM – 3D strategies | 3D-optimised roughing

3D Optimized Roughing

The infeed strategy has been optimised for the ‘Rest material roughing’ machining mode. The optimum infeed value is calculated using the ‘Use infeed optimisation’ option in connection with the ‘Additional chip thickness and depth’ values. The user can adjust the machining to the conditions of the tool. This allows tools with long cutting lengths to be optimally exploited and precisely controlled through the ‘Maximum infeed’ parameter.

Benefit: Faster machining and more economic exploitation of the tool.

CAM – 5-axis strategies | 5-axis swarf cutting with one curve

5 axis swarf cutting with one edge Solidworks

Two new functions ensure greater user-friend­liness for hyperMILL for SOLIDWORKS. A perfect face and an equally perfect curve are created automatically for swarf cutting based on selected geometries via a face selection. Automatic filleting for interior corners ensures optimal machining.

Benefit: User-friendly, fast and easy programming.

What’s new in hyperMILL 2017.1

hyperMILL 2017.1 means greater performance, more process reliability and increased flexibility.
  • Significant auxiliary processing time savings can be achieved during mill turning with hyperMILL millTURN-Linking.
  • Numerous new functions for 2.5D, 3D and 5axis milling increase efficiency.
    These include 3D-optimised roughing and 5axis swarf cutting with a curve.
  • The hyperMILL MAXX Machining performance package has also been extended.
  • And, hyperCAD-S once again features many new highlights.


whats new hypermill 2017 1 en bropdfDownload a hyperMILL Version 2017.1 brochure

What’s new in hyperMILL 2017.1






General | Freely definable tool cutting edge

freely definable tool cutting edge

This extension allows freely definable tool geometries to be used for machining in selected 2D cycles. hyperMILL® uses the free geometries of the tool cutting edge for simulation and collision checking.
Suitable for the following 2D strategies:

  • Contour milling on 3D models
  • Playback milling
  • Plunge milling

Benefit: Flexible tool definition, increased safety during collision checking, use of special tools.

hyperMILL MAXX Machining | High-performance cutting (HPC)

high performance cutting

A new option allows the spindle speed to be adjusted in the plunge macro for roughing. Modifying the spindle speed and specifying a dwell time for the speed change ensures more toolfriendly machining. This option is available for all roughing jobs in the 2.5D, 3D and 5-axis area.

Benefit: Tool-friendly, greater process reliability.

CAM – 2.5D strategies | 2D T-slot milling on 3D models

2d t slot milling on 3d models

This is a new strategy for the efficient machining of T-slots. Various tool references and an optimised axial infeed allow T-slots to be machined safely. All toolpaths are checked for collisions and therefore provide maximum safety.

Benefit: Fast machining of T-slots, user-friendly.

CAM – 3D strategies | 3D cutting edge machining

3d cutting edge machining

This is a new cycle for the optimised 3D machining of cutting edges. Roughing and finishing operations are generated via a 3D curve selection. The rest material machining is generated via the ‘Reference job’ option. Here, the rest material areas of the previous machining operation are also included in each case. Toolpath smoothing ensures a better milling result if the contours are of poor quality. This strategy guarantees efficient machining, particularly for cutting dies.

Benefit: Fast and easy programming of cutting edges.

3D optimised roughing: adaptive pocket

3d optimised roughing adaptive pocket

With the help of this extension, adaptive pockets are fitted into the area to be roughed. As a result, high feedrate cutters can be used more efficiently and the linear machine movements allow higher feedrate values to be achieved than before. The machining can be executed as an adaptive pocket or as an adaptive pocket in combination with conventional roughing. Here, the toolpaths of the adaptive pocket and the remaining machining are optimally connected.

Benefit: Simple and fast programming, fast milling.

CAM – 5 axis strategies | 5-axis swarf cutting with a curve

5 axis swarf cutting curve

Two new functions ensure greater user-friendliness. A perfect surface and an equally perfect curve are created automatically for swarf cutting based on selected geometries via a surface selection. Interior corners are filleted automatically. This ensures optimal machining.

Benefit: User-friendly, fast and easy programming.

CAM mill turning | hyperMILL millTURN-Linking

millturn linking

hyperMILL millTURN-Linking allows multiple job steps, which can be machined with the same tool, to be combined intelligently into a single job step. This eliminates retraction movements between the individual operations and significantly reduces auxiliary processing times. All connecting paths are optimised with respect to the component and checked for collisions.

Benefit: Reduced auxiliary processing times.

Perfect fusion of virtual and real machining

Real machine collisions not only cause damage to machines; they also lead to production losses and associated time delays. This is why the actual machining situation, that is, the machine including controller and PLC, is mapped virtually and simulated based on the NC code in the hyperMILL VIRTUAL Machining Center. In addition, the innovative hyperMILL VIRTUAL Machining Connector provides in-depth, unique networking and synchronisation with the machine.

Reliable and comprehensive simulation: Often, machine movements are only simulated on the basis of internally used data. In other words, simulation takes place before the postprocessor run. In this type of CAM-based simulation, the postprocessor and simulation remain unconnected. With its hyperMILL VIRTUAL Machining Center, OPEN MIND has decided to go one major step further by ensuring that the simulation is based on the NC code after the postprocessor run.* Here, the virtual machine movements correspond exactly to the real machine movements. Only this machine simulation based on the NC code can guarantee reliable collision detection – even before starting on the machine.

*hyperMILL VIRTUAL Machining requires a hyperMILL Virtual Machining postprocessor.

Networking in real time – Machines are opening up as Smart Factory advances. With its hyperMILL VIRTUAL Machining Connector, OPEN MIND is for the first time offering a bidirectional exchange of data with the machine controller. This way, the CAM and machine world are networked in the best possible way and so-called ‘Connected Machining’ becomes a reality – an absolute highlight. Extensive advantages are opened up to companies on this new level of industrial digitalisation to secure long-term improvements in their processes and products.


Zero point alignment with the real machine

Virtual Machining zero point alignment

The machine zero points are aligned with those of the NC program. Clamping errors or incorrect positions are avoided.


Automatic tool comparison

Virtual Machining automatic tool comparison

Tool data from the NC program is automatically compared with the tool data of the machine. If this data does not match, an error message is output and the program run is halted.


NC block synchronisation

Virtual Machining nc block synchronisation

The NC block of the machine can be synchronised with the hyperMILL® VIRTUAL Machining Center; the machining position of the machine simulation after the synchronisation corresponds exactly to the real machine position.


NC program transfer

Virtual Machining nc program transfer

The NC program is loaded directly into the memory of the machine controller.

hyperMILL Collision Avoidance

Better safe than sorry!

Fully automated collision checking and avoidance.

The prerequisite – not just for reliable 5axis machining – is reliable collision checking and avoidance. hyperMILL detects collisions and provides efficient solutions for collision avoidance. Fully automated collision avoidance offers a range of strategies. A collision-free tool angle is calculated automatically for 5axis simultaneous machining. The user can decide which axis of rotation should be prioritised in collision avoidance depending on the machine kinematics. If there are collisions, 3D and/or tilted machining is cancelled, the toolpaths with collisions are left out, and then milling is carried out using longer tool lengths and/or modified tool angles. Furthermore, during roughing, the paths can be moved laterally, thereby allowing greater machining depths. The software can predict tool length extension or reduction to optimise this parameter while assuring collision free toolpaths.

Tool move

hyperMILL Macros

The tool that reduces programming times even further!

Intelligent macros.

A macro is a defined sequence of machining steps comprising tools and technology data for characteristic geometries – so-called features. Together with the highly developed feature technology in hyperMILL, macros offer the potential of reducing programming time. Macros link machining strategies and tools for machining features. They can be saved and called up in the macro database at any time. Macros can be assigned to a feature with a click of the mouse, thereby saving a great deal of time when generating programs.

Thanks to intelligent macros, users can save predefined rules and conditions for every stage of the machining process. hyperMILL automatically assigns and adjusts the job steps to the corresponding geometry based on these rules and depending on geometry information such as diameter, depth, open or closed pockets. Once the required machining sequences have been generated, programming of parts will be generated automatically. Using intelligent macros is very easy because users define the rules in plain language.

hyperMILL Macro EN

hyperMILL Feature Technology

Standardise and automate

Programming with features.

hyperMILL offers a broad array of options for CAD programming that utilise CAD geometry information (features) in a way that significantly reduces programming times. In addition to assigned geometries, features also include information relevant to machining, such as orientation, surface, depth or starting point. These are defined once and can then be assigned to the machining strategy. If the geometry or stored technology parameters are changed in the middle of a process, the changes need only be made in the feature. They are accounted for automatically when a new calculation is performed.

Customized Process Features enable the definition of company standards for similar geometries, thereby automating the programming process even more. This establishes workflows that are saved as technology macros. They can be used for comparable machining tasks. This is based on process-oriented links between characteristic geometries with freely definable sequences of various machining strategies – from 2D, 3D and 5axis milling to turning.

Automatic feature recognition

Detection of geometries, creation of boundaries, leading curves and profiles, as well as grouping of surfaces and holes

Feature Recognition

Pocket features

Automatic pocket recognition, even for pockets without bottoms

Pocket Feature

Hole features

Free definition of holes

Hole Features

Hole features

Definition of simple holes as through holes or blind holes

Hole Features 2

Feature mapping

Importing of features from solids

Feature Mapping

Feature browser

Transparent display of different features or machining sides

Feature Browser

What’s new in hyperMILL 2016.1

hyperMILL 2016.1 with greater performance and many highlights.

From the hyperMILL MAXX Machining performance package for roughing, finishing and drilling with its ‘tangent plane machining’ highlight through to 3D rest material roughing and the Mesh functions in hyperCAD-S.


hyperMILL 2016.1pdfDownload a hyperMILL Version 2016.1 brochure10.00 MB

What’s new in hyperMILL 2016.1







Interactive selection

Interactively position the Z coordinates for surface, depth and clearance plane in the CAD*. These planes can be resized to allow a better visualisation.

Benefit: User-friendly, greater safety.

*only for hyperCAD®-S

Safety level interactive

CAM – 3D strategies

3D-optimised rest material roughing

Following a rouging operation, the new cycle generates HSC-optimised toolpaths for rest material machining. Rest material areas are calculated extremely quickly based on the stock and the user-defined values for minimum stock removal. Rest material boundaries that have been generated can be reused for later machining.

  • New technology with extremely fast calculation times
  • Toolpaths with smooth connection paths for the best possible surface quality
  • Increased feedrates when leaving the stock ensure efficient machining
  • Toolpaths are generated collision-free – completely against the component and rapid link movements are generated against the conveyed stock

Benefit: Machine-friendly, tool-friendly, extremely short machining and calculation times.

3D optimized rest machining3D optimized rest machining detail

CAM – 5-axis strategies

3D/5-axis Z-level finishing

A new option allows the machining direction to be started from the bottom. This offers great advantages to tool and mould making. Toolpaths are checked for collisions at all times.
The tool geometry can be optimally utilised, particularly in 5-axis machining. However, this function is also available for 3D Z-level finishing.

Benefit: Improved surface quality, tool-friendly.

5 axis z level finishing

Tool database

Freely definable tool geometry

Unique und flexible: hyperMILL 2016.1 now offers a free tool definition that makes it easy to define special tools and complex shank geometries. This free tool geometry is used for calculation and simulation purposes.

The shape of the shaft can be defined freely or as parameters. Special shaft shapes or tool holders are completely mapped and checked for collisions.
The shape of the tool cutting edge can also be freely defined in the 5axis rework machining strategy. Exact position identification goes hand in hand with optimal inclination.

Benefit: Flexible tool definition, use of special tools.

Tool geometricTool geometric 2

CAM mill turning

Tool database cutting ream management

Defining and managing mill turning cutting reams using the tool database is more convenient. The user can either choose a free definition or the orthogonal or computational middle point of the tool cutting edge. The user can define different cutting reams for a tool. This allows the tool to be used with different orientations. The cutting ream and reference point are supplied automatically by the hyperMILL® tool database.

Benefit: Visualisation of the cutting position, easier definition.

Cutting point setup

Macro and feature technology

Pocket recognition

This new function allows open and closed pockets to be machined very efficiently. Areas on different planes are recognised automatically. However, the areas can also be defined manually. Colour coding makes it easier to find areas in complex pockets.

Benefit: Simple and fast programming of complex pockets.

Macro Pocket recognition

hyperMILL MAXX Machining

HPC software for roughing, finishing and drilling

With its hyperMILL MAXX Machining HPC package, OPEN MIND has developed a high-performance solution for:

  • Roughing
  • Finishing
  • Drilling

Trochoidal toolpaths ensure extremely fast material removal. Innovative strategies for barrel cutters allow for finishing in record time. Milling tools tilted in cutting mode can also drill holes in materials that are difficult to machine both quickly and easily and without the need for any predrilling.

Animation HPC en

Tangent plane machining

‘Tangent plane machining’ is designed specifically to machine planes. This innovative milling strategy takes advantage of the tool shape in order to achieve perfect surfaces for plane machining. Intelligent automated functions ensure optimum tool orientation and fit so that hard-to-reach areas can also be machined efficiently. Compared to conventional methods, time savings of up to 90 per cent can be achieved when a conical barrel cutter is used.

hyperMILL Maxx Machining plane machining

CAD integration: hyperCAD-S

Mesh – Preparing meshes quickly for milling

Forged and cast parts, clay models and moulds: 3D surface scanners have a wide range of uses. The high-resolution and precise set of scanned data – a so-called mesh – is mostly combined with a large quantity of data.
hyperCAD-S Mesh allows the CAM programmer to very quickly generate a perfect basis for milling. The CAM programmer can repair any possible mesh deviations, perform metrological analyses and checks and prepare meshes conveniently for milling.

hyperCAD S Mesh

hyperCAD-S Mesh features six new functions for machining meshes.

Smooth meshes. This function repairs deviations.

hyperCAD S Mesh smooth

Decimate meshes. This function reduces the mesh density while retaining the geometry properties. The reduced data volume helps to accelerate the calculation of models.

hyperCAD S Mesh reduced

Fill mesh areas. This function closes holes in meshes in a simple and convenient way.

hyperCAD S Mesh fill

Separate mesh clusters. This function deletes meshes that are not connected.

Mesh from faces. A mesh can be generated from faces, open and closed solids.

Split meshes. Mesh elements can be split using a planar entity. All the cut triangles are regenerated to ensure that a smooth cut is achieved.


Viewer for CAD data, Viewer for CAM data: more transparency, fewer errors

hyperCAD-S Viewer: for viewing CAD files

hyperCAD-S Viewer is ideal for departments, such as job planning or quote calculation, that simply want to take a brief look at their CAD data. The software features an extensive package of CAD interfaces: hyperCAD files, IGES, STEP, DXF/DWG, point cloud, Parasolid and optional Catia V4 and V5, Autodesk Inventor, Siemens NX, SOLIDWORKS, PTC Creo.

hyperCAD S Viewer

hyperMILL SHOP Viewer: for viewing CAM data from hyperMILL

In addition to CAD data, hyperMILL SHOP Viewer also allows the user to view CAM data from hyperMILL. Data that is relevant to production can be visualised and simulated directly next to the machine. Detailed information on hyperMILL jobs and on the geometry and component structure is immediately and consistently available to all parties. This improves communication in the manufacturing process. ‘Pack&Go’ is a new function in hyperMILL SHOP Viewer: It allows configuration files such as the machine model, postprocessor and POF files to be integrated into the project file. This ensures that the files can be easily opened on all hyperMILL workstations.

hyperMILL SHOP Viewer

Shape contours

The shape contours of a face or component can be created quickly and easily with this new function. Contours for CAM machining can be created more quickly in face, solid and mesh models.

Benefit: More user-friendly, fast preparation of contours.

hyperCAD S shape contour

New sketcher

The new sketcher allows design sketches to be conveniently created. The lengths and positions of lines, for example, can be entered in mini dialog boxes precisely by value. Common dependencies such as vertical, horizontal and tangential are displayed interactively during construction. These sketcher functions can also be applied to existing curves, faces and boundaries.

Benefit: User-friendly, fast design.

hyperCAD S sketch overview

Swarf cutting faces

Perfect faces can be created easily and quickly for swarf cutting, based on existing geometries. ‘Interior corners’ are filleted automatically. This ensures optimal milling.

Benefit: More user-friendly.

hyperCAD S perimeter milling surfaces


What’s new in hyperMILL 2016.2

hyperMILL 2016.2 offers even greater performance and is easier to use than previous versions.
  • The new 3D plane level machining and further optimisations for 3D milling enable more efficient programming.
  • Highlights such as the 5 axis-optimised rest material roughing ensure extremely short calculation and machining times.
  • 5 axis tangent machining has been added to the hyperMILL MAXX Machining performance package.
  • In addition, hyperCAD-S once again includes numerous highlights and new features.


hyperMILL 2016.2pdfDownload a hyperMILL Version 2016.2 brochure6.58 MB

What’s new in hyperMILL 2016.2







Optimised menu navigation

hyperMILL is even more user-friendly than before. A new shortcut menu ensures even simpler and faster programming. The menu windows are structured more clearly and feature new icons.

  • Visibility of toolpaths: The toolpath display can be switched on and off using a visibility icon.
  • Feature generation: Selected areas of a job, such as faces and contours, can be generated as a feature and reused in later jobs.
  • Feature machining: You can now manually sort selected geometries in a feature and arrange them as required.
  • Global clearance plane: You can globally define the clearance plane for a project, which is then adopted automatically for all jobs.
  • Automatic report generation: The hyperVIEW® Report from hyperMILL can now be generated automatically with the click of a button.

Optimised menu navigation

JT format

hyperMILL supports the JT neutral 3D data format for importing model data. The JT format has become the industry standard, especially in the automobile industry.

Benefit: Fast import of JT data.

TDM Systems interface

The new integration in hyperMILL® enables fast data exchange with the TDM Systems tool management system.

Benefit: Easy to use, fast tool generation.

TDM Systems interface

Tool database

TOOL Builder

The new hyperMILL TOOL Builder allows you to quickly and easily create holders for machining in hyperMILL. An intuitive-to-use wizard allows you to directly import tool holder data from supplier catalogues in IGES or STEP format. The holders, extensions and turning tool holders generated can be assembled into an NC tool in the hyperMILL tool database. All components are fully checked for collisions. This way, tool holders and extensions for milling can be imported to hyperMILL with the original data from the supplier. hyperMILL millTURN tools such as holders and boring bars can now be imported 1:1 from the supplier catalogues. This allows complex holders to be mapped true-to-detail in hyperMILL.

Benefit: Simple and fast tool holder creation.

TOOL Builder en

Stock management

Interactive stock chain

The user can create a stock chain for any number of jobs or for all jobs simultaneously. For each job, a resulting stock is generated for the previous job step. When a cycle is recalculated, stock is generated even for jobs that do not hold or carry stock.

Stock generation

A history is now created during manual stock generation. This allows you to keep track of which stock has been used for which job. This history can be updated at any time.

Stock display

There is an option for hyperMILL to automatically display the active job’s resulting stock and stock removal.

Benefit: Simpler programming, improved transparency.

Stock management

CAM – 2D strategies

2D contour milling on 3D models

A new feature for feedrate checking allows the feedrate to be adapted specifically for individual contour elements. You can define the feedrate for individual contours or specific segments on a contour. The ‘Edge control’ option allows the feedrate to be adapted automatically to the tool and component geometry.

Benefit: Protects the tool, simple programming, increased safety.

2D contour milling on 3D models

CAM – 3D strategies

3D plane level machining

This new cycle enables the finishing of planes. You select the area to be machined by making a simple selection of plane faces or via an auto­matic selection in the plane. The toolpaths can be optionally trimmed against a stock.

Benefit: User-friendly, fast programming.

3D plane level machining

hyperMILL MAXX Machining

5 axis tangent machining*

5 axis tangent machining has been added to the hyperMILL MAXX Machining finishing module. The cycle now supports the conical barrel cutter for semi-finishing and finishing operations on any continuous faces.

Intelligent automated functions ensure optimum tool orientation and fit. In collision areas, the tool tilts upwards away from the contact point or guiding angle.

A new feature for Z-level and ISO machining enables simple selection of component surfaces. The cycle creates the toolpaths fully automatically without a special contour selection.

Benefit: Simple programming, faster finishing.

*Not included in maintenance contract.

5 axis tangent machining

CAM – 5 axis strategies

Conical interpolation

The ‘Fast movement optimised’ option allows tools to be positioned around the pole in conical movements. This prevents singularities and generates simultaneous 5axis movement. Most machine tools can carry out this movement much more dynamically.

Benefit: Shorter machine times, movements are easier on the machine tool.

5 axis optimised rest roughing*

This new cycle generates high-speed cutting (HSC)-optimised toolpaths for rest material machining, based on a preceding roughing operation. An advantage of indexed 5 axis machining is that you can use shorter tools that guarantee higher stability and greater perfor­mance. The strategy is especially efficient for cavities and hard-to-reach areas.

5 axis optimised rest roughing

Indexed machining

You can define the tilt angles for the B and C axes easily and quickly using two modes. The ‘Planes’ option allows you generate the tilt angle from the plane normals. In ‘3D mode’, tilt angles are generated automatically within a defined range of angles. All connecting paths between the tilt angles are optimised and fully checked for collisions.

Benefit: Machine-friendly, tool-friendly, extremely short machining and calculation times.

*Not included in maintenance contract.

CAD integration: hyperCAD-S


The new ‘Wrapping’ command allows you to wrap plane curves or texts onto cylindrical and rotational faces. The wrapping does not distort the geometry. The direction, scaling and mirroring can be modified.

Benefit: Fast generation and milling of engraved contours.

hyperCAD S wrapping

Compare and merge

This function allows the user to compare various versions of CAD models and select modified geometry elements to insert them into an existing document. All unmodified geometries remain in hyperMILL so only updated areas need to be reprogrammed.

Benefit: New versions can be adopted automatically by an existing document.

hyperCAD S compare merge


The new function improves communication between hyperMILL programming workstations and hyperMILL SHOP Viewer workstations. The user has the option to highlight areas in a model and add text information to these areas. The profile and machining status are documented and can be checked at every workstation using a preview. Markups can also be used in read-only documents in hyperMILL SHOP Viewer.

Benefit: Easier exchange of machining tips and information.

hyperCAD S markups

Convert to analytical

The NURBS elements of faces and curves are converted to analytic elements such as lines, arcs, cylinder faces, rotational faces and planes. Splines are converted to lines and arcs, for example. This conversion enables faster, smoother machining.

Benefit: Simple conversion of NURBS elements, better milling

Mesh functions

The ‘Project’ command allows curves to be projected onto a mesh surface, and then be used as a boundary entity for hyperMILL® programming.
The ‘Intersect curve’ command allows cutting curves to be created between two meshes.

Benefit: Easy preparation of meshes for milling.

hyperCAD S Mesh functions

hyperMILL CAM Software

hyperMILL CAM software

A single CAM solution for all your machining needs, providing efficient and continuous processes.

For efficient and continuous processes.

With hyperMILL, both simple and complex geometries can be programmed efficiently. Workpieces can be completely machined in a single setup thanks to the broad range of machining strategies. The advantages: continuous and more efficient processes, reduced processing times and higher reliability.

In addition, hyperMILL offers several options for automated programming, reducing machine cycle times and optimising processes. Examples of this include sophisticated feature and macro technology, automated functions such as mirroring and transforming, functions that minimise auxiliary processing times such as job linking or production mode, and fully automated collision checking and avoidance.

  • Easy, time-saving programming with automated functions such as transformation and mirroring
  • Intelligent functions such as job linking or production mode reduce auxiliary processing times
  • Automatic indexing for 5axis machining that saves time and is easier on the machine
  • Multiple 5axis strategies for cavity and surface machining
  • Fully automated collision checking and avoidance for the highest process reliability
  • Functions for HSC machining and high-performance roughing
  • 2D, 3D, HSC, 5-axis and mill turn strategies combined in a single interface
  • The world’s leading 5axis technology
  • Special applications seamlessly integrated in hyperMILL
  • A unified postprocessor for turning and milling


hyperMILL brochurepdfDownload a hyperMILL brochure.3.41 MB

The complete system for efficient and reliable CAM programming.