Additive Manufacturing and Advanced CAD CAM System Integration

OPEN MIND demonstrated from November 17 to 20, 2026, at booth A18 in hall 12.0 of Formnext in Frankfurt, how the CAD/CAM system hyperMILL supports the additive manufacturing and subtractive post-processing of workpieces. Intelligent and seamless processes extend beyond hybrid machines, with the BEST FIT function eliminating specific sources of error during machine transitions.

Core Technology and System Architecture
The exhibition focused on hyperMILL ADDITIVE Manufacturing for the convenient programming of NC codes for metal deposition using Direct Energy Deposition (DED) and Wire Arc Additive Manufacturing (WAAM). These highly complex 5-axis simultaneous machining operations require a uniform material flow that differs significantly from conventional machining paths. For collision avoidance, hyperMILL VIRTUAL Machining is based on the actual NC code as well as the digital twin of the machine. The ADDITIVE Manufacturing module, fully integrated into hyperMILL, enables a seamless software solution for efficient hybrid machining on a single system.

Deployment or Implementation
Implementation is achieved through seamless process chains ranging from CAD design through CAM programming for additive and subtractive machining to NC-code-based simulation. hyperMILL CONNECTED Machining directly interconnects CAD/CAM software and machine systems. For larger production volumes, where a multi-stage process chain is more economical than pure hybrid machines, BEST FIT solves the challenge of aligning 3D-printed blanks. Instead of manually positioning components, BEST FIT adapts the NC code to the actually recorded position of the workpiece within the machine workspace, which is imported via measurement and simulation as a digital twin.

Industrial Applications
The presented functions target demanding industries such as mold and die making with conformal cooling channels, medical technology for custom medical devices, the aerospace industry for bionic lightweight structures, and innovative material combinations. As David Bourdages, Product Manager Additive Manufacturing at OPEN MIND Technologies AG, explains: 'The more additive processes become established, the more important it becomes to create robust, seamlessly networked production processes. This is primarily a software question, and hyperMILL is perfectly suited for this.'

Operational Impact and Performance Metrics
The use of seamless software solutions eliminates manual alignment errors and reduces setup times during the post-processing of additively manufactured blanks that are produced close to net shape. The NC-code-based simulation utilizing the digital twin minimizes collision risks and increases process stability in complex 5-axis simultaneous machining. Through the seamless networking of CAD, CAM, and machine technology, companies optimize their manufacturing efficiency in hybrid and additive metalworking.

Edited by Maria Brueva, Induportals editor - adapted by AI.

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