hyperMILL CAD/CAM
hyperMILL® is a complete modular CAD/CAM solution that provides state-of-the-art CAM technologies on a dedicated CAD platform: from 2.5D, 3D, 5-axis milling and turning strategies to solutions for additive manufacturing and machining processes such as high-speed cutting (HSC) and high-performance cutting (HPC). Whether it’s automation, simulation or virtual machines – pioneering technologies expand our product range and enable end-to-end digital process chains. The hyperMILL® range of services is rounded off by special applications, the best possible interaction with all common CAD solutions and a customer-focused service offering.
Highlights
hyperMILL® offers fully integrated CAD functions developed specifically for CAM programmers, allowing fast and flexible creation and editing of points, curves, surfaces, solids, and meshes. CAD for CAM features like automatic surface extensions simplify complex tasks and reduce preparation time. Combined with advanced 5-axis strategies, reliable postprocessors, and powerful automation options, hyperMILL® enables faster programming, greater process reliability, and high-quality results—trusted by manufacturers in aerospace, automotive, medical, mold & die, and other demanding industries.
- Complete CAD/CAM Solution – hyperMILL® offers advanced machining strategies, reducing setup time and improving accuracy and surface quality for complex parts.
- Error-Free Postprocessors and Virtual Machine- hyperMILL® postprocessors generate, optimize and simulate precise NC code, eliminating errors and manual adjustments.
- Competent and Passionate Support & Service - Expert support, with machining backgrounds, ensures fast troubleshooting, regular updates, and ongoing training for better productivity.
Module
NX CAM enables programming from 2.5-axis to 5-axis simultaneously, as well as synchronized turn-mill operations, modular and tailored to individual requirements. This is supported by an NC simulation of DMG MORI machine tools, including 3D collision control and real-time material removal.
- From 2.5D to multi-channel machining
- Established milling strategies for individual machining
- Modular design tailored to customer requirements
High Precision Machining is a CAM functionality designed to generate toolpaths with extremely fine resolution, enabling ultra-precise surface finishes and dimensional accuracy in the micrometer range. The system calculates the toolpath directly on the original CAD surfaces, minimizing geometry approximation and NC point deviations. This level of precision ensures that adjacent toolpaths and strategy transitions blend seamlessly, maintaining consistent contact conditions and surface quality without secondary operations or manual rework. Several intelligent features contribute to this result, including adaptive point distribution, automatic surface extension, and collision-safe barrel cutter utilization.
The key high-precision techniques include:
- High-Precision Surface Mode
- Smooth Overlap
- Automatic Face Extension
- Barrel Cutter Integration
MAXX Machining is hyperMILL®’s powerful performance package developed to significantly reduce machining time while improving process reliability and surface quality. It provides dedicated high-performance strategies for roughing, drilling, and finishing across 2.5D, 3D, and 5-axis applications. Each module is designed to fully exploit modern machine capabilities and advanced tool geometries like barrel cutters enabling faster cycle times without compromising accuracy or tool life. The package includes:
- High-Performance Drilling: Enables 5-axis helical drilling without the need for predrilling.
- HPC Roughing
- Up to 90
- Increased Productivity & Tool Life
hyperMILL® ADDITIVE Manufacturing and Hybrid Manufacturing integrates additive and subtractive processes in a single CAM environment. It supports 5-axis Directed Energy Deposition (DED) allowing precise material build-up and milling within one workflow. hyperMILL® ensures accurate stock tracking, unified tool management, and collision-free operations.
hyperMILL® PROBING integrates in-machine measurement directly into the CAM process, allowing setup, control, and inspection operations to be programmed like any other toolpath. It supports both 3-axis and indexed 5-axis probing with full collision checking and seamless NC code generation.
- Supports setup, in-process control, and final inspection within one workflow
- Enables automatic deviation compensation based on measured values
- Ensures safe, collision-free probe movements with virtual machine simulation
Features
hyperMILL® 2025 offers advanced deburring strategies to remove sharp edges and burrs directly on the machine, improving both part quality and process reliability. These strategies are available in both 3-axis and 5-axis modes, enabling efficient and collision-free deburring of holes, cross features, and part edges with minimal programming effort. Intelligent feature recognition and automated toolpath generation streamline the process.
Available Strategies:
- 5-axis Hole Deburring: Automatically detects and deburrs sharp edges on holes and intersecting holes using indexed or simultaneous 5-axis motion.
- Hole Brushing: Uses a dedicated brushing tool with configurable parameters to clean and deburr threads, cross holes, and similar features.
- 5-axis Deburring: Enables fast, comprehensive edge deburring using ball or lollipop cutters with automatic tilt and collision avoidance.
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
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.
hyperMILL® integrates seamlessly with SOLIDWORKS, and Autodesk Inventor, enabling CAM programming directly within the CAD environment. This ensures a unified workflow, full model associativity, and faster, error-free toolpath updates.
A streamlined visualization tool for the shop floor, the hyperMILL® SHOP Viewer puts both CAD and CAM data directly in front of machine operators—right at the control panel. It enables quick access to and simulation of finished toolpaths, material removal, and internal machine sequences before manufacturing begins, enhancing process safety and reliability. Operators can examine geometry, features, and toolpaths, take precise measurements, and spot potential errors in advance. Viewer files optionally include machine models, postprocessors, and configuration data, so projects can be opened seamlessly on any workstation without extra setup
Videos
High-performance, complete CAM solution | NC programming | hyperMILL
Success stories
Momentum Manufacturing Group (MMG), a leading U.S. metal manufacturer with over 250 CNC machines, produces tight-tolerance parts for the semiconductor and medical sectors using advanced 5-axis machining. By standardizing hyperMILL® across its facilities, MMG reduced programming time by 25% and halved machining times using high-performance roughing and circle-segment tools. The software enabled efficient programming of complex components with fewer setups and superior surface finishes.
Western Precision Products (WPP), a precision aerospace machining firm, produces both miniature and large, structural aerospace components using lathes, Swiss machines, mill‑turn centers and DMG MORI 5‑axis machining centers. They implemented hyperMILL® across four workstations to automate tool orientation, collision‑checked toolpaths and macros for holes, chamfers, and finishing, achieving a 65% reduction in setup time and 30% fewer setup parts.
Urschel Laboratories, a global leader in food-cutting machinery with over 400 employees, adopted hyperMILL® to boost efficiency on their DMG MORI 5-axis machines. The software’s integration with SOLIDWORKS and advanced toolpath strategies allowed faster prototyping and improved accuracy for complex parts. hyperMILL® enabled Urschel to reduce setups and streamline production of high-tolerance components for their cutting-edge food-processing equipment.
Ramco Machine, LLC, a family-owned CNC prototype shop, specializes in complex milled and turned parts for sectors like robotics, medical devices, vintage Ferrari restoration, and NASA satellite components. Their first 5-axis DMG MORI DMU 65 FD monoBLOCK mill-turn center enabled manufacturing of camera mount brackets in Invar to tolerances such as 0.050″±0.001″ thickness and 0.001″ perpendicularity. With hyperMILL® CAM software they were able to accurately collision‑check 5‑axis profile finishing paths, supporting fast turnaround and tight tolerances for unique prototype machining.