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hyperMILL® CAD/CAM software: What’s new in 2025?

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    hyperMILL® 2025 offers you even more performance and efficiency, both for CAD and CAM.

    With the new tessellation algorithm and the new, simplified element display for CAD models, as well as improved algorithms of our 3D strategies, you benefit from noticeably faster working and even more precise processing results.
    A highlight of the new hyperMILL® release are three innovative strategies for deburring holes and part edges – for maximum flexibility and the highest quality. In addition, the new 5-axis automatic tool orientation mode ensures optimized machining and guarantees efficient and reliable tool paths, even for the most complex components.

    Brochure

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    Version 2025

    CAM software hyperMILL®.

    What's new in 2025?
    pdf | 3 MB

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    CAD

    Improved linear sweep

    hyperMILL® now allows you to easily extrude even highly complex sketches with a defined angle of inclination. Surfaces that intersect with themselves or others are automatically trimmed. This allows you to quickly and accurately create complex surfaces, such as those needed for molds or electrodes.

    Benefit: No rework required for highly complex sketches.

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    Optimized performance for large component groups

    Thanks to our new “Switch visibility on/off” function, you benefit from significantly improved performance when working with large assemblies. Even before loading a file, all layers can be set to non-selectable so that the model responds more smoothly from the start. You can activate individual layers as required to carry out specific edits.

    Benefit: Smooth workflows for complex models and large projects.

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    Triple tangential fillet

    With hyperMILL® you can now create seamless fillets between three adjacent surfaces while maintaining full continuity. This function saves you valuable time when modeling complex geometries, such as turbine blades, while ensuring the highest precision and quality of your models.

    Benefit: Fast and precise creation of triple tangent fillets.

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    New tessellation technology

    We have developed an entirely new tessellation technology that significantly improves performance when loading as well as during daily work. Curves, surfaces, their edges, and solids use the same setting option and can be adjusted via a single parameter.

    Benefit: Significantly improved performance and simplified operation.

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    CAM

    3D Optimized Roughing

    The pocket milling algorithm has been redeveloped for the roughing mode of the strategy in order to achieve greater efficiency during roughing and better machining control. A benefit of the new version is realized when machining with large lateral infeeds and remaining material. Additionally, you can define a contour radius and a path radius, allowing you to better control toolpath roundings. The contour radius is used for toolpaths along the model geometry, while the path radius is used for all other offset paths.

    Benefit: Faster rough machining and improved behavior with large infeeds and rest material.

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    New strategies for precise deburring

    Burr-free edges and holes are not only functionally important, but also an essential component of a high-quality end product. With hyperMILL® 2025 you have a comprehensive selection of deburring strategies available directly at the machine.

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    The optional license “5-axis Deburring” enables the use of both strategies: “5-axis Hole Deburring” and “5-axis Deburring” in 5-axis mode. The 3-axis mode is included as standard in the hyperMILL® 3D package.

    Left | 5-axis Hole Deburring

    This new strategy makes it very simple to deburr sharp edges on holes and intersecting holes. Thanks to our intelligent function, the CAM Plan, all holes are automatically recognized, and all sharp edges in the model are marked. You only need to select the desired edges, and the strategy automatically calculates all toolpaths. The strategy supports a 3-axis mode, which is already included in the hyperMILL® 3D package, and a 5-axis mode. In the 5-axis mode, machining is indexed where possible. If this is not feasible, it is carried out with 5-axis simultaneous movements.
    Benefit: Fast, simple, and safe deburring of holes.

    Center | Hole Brushing

    Use this new strategy to deburr or improve the surface quality of cross holes, threads, or other features with a special brushing tool. The machining process is divided into different phases, and for each phase, machining parameters such as spindle speed, feedrate, coolant, and dwell time can be defined. Under the “Parameters” tab, settings for the machining area, brushing direction, and the number of repetitions can also be made.
    Benefit: Easy programming of a brushing tool and deburring of holes and other features.

    Right | 5-axis Deburring

    This new hyperMILL® strategy provides you with a fast and effective solution to deburr all sharp edges of a part. You can choose between a 3-axis machining, which is already included in the hyperMILL® 3D package, and a 5-axis machining mode. Thanks to the 5-axis option, you can reach more component edges, and the necessary inclinations as well as collision avoidance are generated automatically. The edges are preferably machined with a fixed approach. If this is not possible, simultaneous machining is used. This strategy supports both lollipop and ballmill cutters.
    Benefit: Fast and effective deburring of component edges.

    5-axis ISO Machining

    Use our new 5-axis strategy* to machine individual or a few contiguous surfaces according to the course of the ISO lines (U and V). The functions that you are already familiar with from 3D ISO Machining can now also be used for 5-axis machining. In addition to feed adjustment for curvatures and 3D radius correction, the high-precision surface mode can be used with our True-Shape Technology.

    Benefit: 5-axis machining of ISO surfaces with increased surface quality and programming support through intelligent algorithms.

    *Licensing required.

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    5-axis Profile Finishing

    We have fundamentally revised this strategy and offer you a new, improved version of 5-axis Profile Finishing. Many familiar and innovative features from “3D Profile Finishing” are now also available for 5-axis machining.
    Additionally, the strategy offers a new algorithm for the automatic tool orientation strategy. Utilize familiar functions such as smooth overlapping, automatic milling surface extension, trimming to the milling area, adjustment of curvature feedrate, or 3D path compensation to make surface machining more efficient, easier, and faster.
    With the option “True-Shape Point Distribution”, you achieve an optimal point distribution for machining. This leads to a higher surface quality and consistent machine movements.

    Benefit: Faster and simplified programming, higher surface quality, and programming support through intelligent algorithms.

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    Impeller Blisk Point Contact Machining

    Avoiding deformations and vibrations when finishing thin or unstable blades usually requires a high number of individual pre-finishing and finishing programs. With the new “Step-bystep finishing with blending” option, you can reduce this effort. Finishing jobs are divided into short steps/areas, with a blending cut reducing the material thickness directly before each of these steps. Finishing can therefore follow directly after roughing without pre-finishing.

    Benefit: Optimized programming and finishing machining of blades.

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    V-sketch for turning contours

    Create a special V-sketch for turning in an easy and automated way. Starting from a 3D model that is typically designed with nominal dimensions, the V-sketch with turning contour is generated almost fully automatically. A command is used to define horizontal dimensions and assign corresponding tolerance specifications. Based on these values, the turning contour can be moved to the center of the tolerance. Thanks to the new V-sketch for turning, you can also prepare your turning contour with undercuts, edge breaks and tolerances quickly and efficiently for programming.

    Benefit: Fast and dimensionally accurate turning contour creation, based on a 3D model.

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    Technology

    Job calculation with virtual machine

    With the new option “Use VM for calculation”, hyperMILL® uses the machine model directly during tool path calculation. Collision control and avoidance take place considering the machine geometry and limits. The result: more precise and optimized tool paths, especially in tight spaces or when the machine head is working close to the part or machine limits. Residual material areas that arise due to collisions or machine limits can be reworked as usual with other strategies and without visible transition thanks to the “Smooth overlap” option.
    The usual flexibility remains: The option can be specifically used for individual machining jobs, and a machine change is still possible without recalculation.

    Benefit: Calculation of collision avoidance using the machine model.

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    Solution selection: Closest C-axis angle

    When selecting the preferred direction under the “NC Solutions” tab in the job setup, you can now select the option “Closest C-angle”. This allows you to control the positioning solution specifically via a preferred C-axis position. Plus and minus solutions are selected so that the C-axis remains as close as possible to the defined angle – even when 5-axis machining. With a hyperMILL® VIRTUAL Machining Optimizer license, possible collisions or axis limit violations can be prevented during NC generation.

    Benefit: Avoiding large C-axis rotations in non-pole situations, increased machining accuracy, and reduced programming effort.

    – A large machine head movement is visible.

    A large machine head movement is visible.

    Linking with dynamic stock

    You can now use the “Use dynamic stock” option for smooth linking movements generated by the hyperMILL® Optimizer. An updated stock is automatically generated for all machining jobs in the job list and taken into account when calculating the linking movements. This allows you to create linking movements that are optimized for the actual stock conditions.

    Benefit: Optimized linking movements.

    – On the left image, a large machine head movement is visible; on the right image, the optimized movement

    On the left image, a large machine head movement is visible; on the right image, the optimized movement

    Automatic stock chain

    The new version provides you with a completely new stock handling system in hyperMILL®. Fully automatic, powerful, intelligent, and applicable across all all types of machining, from drilling, turning and milling to additive machining. Activate the option “Automatically create stock chain” in the job list under the definition of a resolution, and hyperMILL® automatically creates all stock models in the correct order. If a machining job is deleted or reordered, hyperMILL® adjusts the stock chain accordingly. Likewise, a machining job can be removed from the stock chain if necessary. Otherwise, no user interaction is required, and from creation to handover to the simulation or the virtual machine, hyperMILL® handles all stock models.

    Benefit: Simplified and user-friendly handling and creation of stock models.

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    Optimal barrel cutter

    Thanks to the new function “Optimal barrel cutter” under the “CAM” tab, you can analyze the use of a barrel cutter for your machining areas. The analysis uses one of the three types of barrel cutters: conical, tangential, or general. For each barrel type, a range for the base diameter and barrel radius can be defined, so that the optimal cutter geometry is displayed during the analysis. Additionally, you can optimize the usable barrel radius through the analysis of the lead angle or determine the optimal barrel radius using the contact parameter control and the maximum barrel radius distance parameter. This function helps you select a suitable barrel cutter and ensures its optimized use.

    Benefit: Simple and fast analysis for the optimal use of barrel cutters.

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    hyperMILL® AUTOMATION Center Controller

    The new hyperMILL® AUTOMATION Center Controller enables you to easily manage and structure self-developed scripts and script blocks. This gives you a better overview and access to your automation scripts. Create favorites and organize your scripts within them. Filtering for specific scripts is always possible. To help understand this function, a set of example data that you can customize and expand is provided with the release of AUTOMATION Center Controller. In the controller, combined scripts or script blocks can be executed automatically. To do this, the sequence must be saved in a favorite.

    Benefit: Improved organization and application of automation scripts.

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