OPEN MIND Technologies AG

OPEN MIND Technologies AG (9)

OPEN MIND Technologies AG has introduced hyperMILL® 2018.2, the latest version of its advanced, comprehensive CAM software. hyperMILL® 2018.2 offers a range of enhancements and new features for 3D Shape Z-level Finishing and 3D Optimized Roughing, greater CAD functionality and more.

For reduced programming times and improved milling, 3D Z-level Shape Finishing, available in hyperCAD®-S, has two new features. "Automatic face extension" can be used during CAM programming to automatically extend the selected milling surfaces, eliminating manual CAD work and resulting in cleaner corner cuts. Also, 3D Z-level Shape Finishing now has the ability to support conical barrel cutters in addition to general and tangential cutters.

During 3D Optimized Roughing, multiple allowances are now recognized and accounted for when using free tool geometries, resulting in easier programming and a high level of flexibility for defining special tools. hyperMILL® 2018.2 can define different allowances and adapt the machining process accordingly. High-feed cutters have a special cutting geometry that is easy to define using tool management, and hyperMILL® 2018.2 uses the free geometries of the cutting tool edge for calculation, simulation and collision checking.

"Keeping the hyperMILL® suite at the forefront of CAM technology, we are pleased to offer our customers improved CAM strategies and enhanced CAD tools for even greater machining productivity through our new release of hyperMILL® 2018.2," said Alan Levine, Managing Director of OPEN MIND Technologies USA, Inc.

New hyperMILL® 2018.2 functionality also includes several enhancements to its hyperCAD®-S module, including the ability to measure and record the distances between two shapes such as face models, solids, meshes or stock. In addition, for easy changes to milling boundaries and turning contours, hyperMILL® 2018.2 offers a 'V sketch' command that assigns geometric constraints to 2D contours. When individual contours are changed, the sketch is automatically updated using their dependencies.

The electrode module, which provides quick designing of die-sinking electrodes, offers a new Virtual Electrode function for securely creating electrode copies which are checked for collisions, and can be assigned new technology values or the values of the master electrodes. For easier analysis, the reference system and eroding position for each electrode copy are included in a report.

Friday, 10 August 2012 09:38

OPEN MIND releases hyperMILL® 2012

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OPEN MIND Technologies AG introduces the new version of its hyperMILL® CAM solution. Highlights of the 2012 version include automatic programming options for rectangular pockets, optimisations for 3D roughing and new strategies for 5axis machining of impellers and blisks. Other changes improve calculation times and programming times.

The new 'adaptive pocket' machining mode allows for automatic programming of rectangular pockets. Within a machining job, classification occurs automatically in closed and open pockets and rectangular levels. According to the various accessibility conditions for the tool and relative sizes of the tool and pocket, hyperMILL® automatically selects the most suitable machining method: spiral, contour-parallel or peeling. The optimised clearing movements take place in long, straight paths with constant cutting conditions. Critical full cutting areas are parameterised separately, allowing control over feedrate values and reduced production times.

Time-saving 5axis strategies. The ways in which machining times have been shortened are both simple and ingenious: During 5axis shape offset machining with hyperMILL®, users now avoid redundant movements thanks to the new axial sorting option that makes it possible to divide machining by area. This allows corners or pockets, for example, to be machined individually one after another. The user can decide whether to create toolpaths with offset level sorting or axial sorting.

There are several new features for roughing in the 5axis impeller and blisk package. For machining of impellers, for example, it is now possible to divide the machining region into a left and right pocket between the main blade and the splitter. This new option means that these areas can now be machined with different tools in a targeted manner.

The flank mode during roughing enables swarf cutting near blade surfaces. The user can decide whether to use the swarf mode for every step or just for the last step. This extension results in a consistent stock allowance for finishing. Production time can also be reduced here as preliminary finishing can be skipped.

Optimal tool use. hyperMILL® 2012 supports tapered tools for 3D ISO machining - including automatic collision avoidance. In the process, the entire tool is checked for collisions against the model, which ensures high process reliability. Tapered tools offer more stability, reduce tool vibrations and improve surfaces simultaneously.

For turning operations, hyperMILL® functionality has been extended to include inclined grooving. This is why offset tools can now also be used. The tool database has therefore been expanded to include these recessing tools.

Toolpaths and tool life. Pocket milling has been improved in the 3D roughing area. As a result, for the machining of pockets, the ramp is moved continuously in one direction. The pocket is then cleared from the outside in. Advantage: Thanks to the continuous inward movement of the ramp, the tool path is optimised, and zig-zag movements are avoided.

This software release will be debuted at the IMTS trade show (booth E-3351) in Chicago from September 10 through 15.

For more information, visit:

In this special CAD/CAM webcast series, SolidWorks presents world-class CAM solutions that are fully integrated into SolidWorks software to help you reduce product manufacturing costs, shorten lead times, and increase throughput and yield.

Don’t miss this special CAD/CAM series and discover SolidWorks design capabilities combined with your choice of CAM solutions, all in one software package.

Register today and evaluate the best integrated CAD/CAM tool for your organization.

Wednesday, October 19, 2011
2:00 PM - 3:00 PM EDT

The webcast will feature OPEN MIND, developers of hyperMILL®, a leading CAM software for 2-axis through 5-axis milling and drilling, and mill-turn solutions.

PRESENTERS: Craig Therrien, Product Manager, Dassault Systèmes SolidWorks Corp.; Ernie Dickieson, Senior Applications Engineer, OPEN MIND Technologies USA, Inc. & Chris Taylor, Owner, 5th Axis, Inc.

For more information or to register, visit:

Tuesday, 11 October 2011 09:55

OPEN MIND releases hyperMILL® 2011

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OPEN MIND Technologies AG has released hyperMILL® 2011. The new version is ready for immediate download. New automated functions and innovative technologies in hyperMILL® helps to reduce machining costs and times. The new features include intelligent macros, 64-bit support, Application Programming Interfaces (API) and Customised Process Features (CPF). New strategies such as 5axis shape offset roughing and finishing are allowing an even more efficient programming.

hyperMILL® is a modern programming environment offering forward-looking solutions for 2D, 3D, HSC and 5axis simultaneous machining. Users can draw from a wide range of functions for optimised processes, time-saving, comfortable workflows and thus efficient machining.

New strategies and optimisation functions are available in 2D machining as well as 5axis simultaneous milling and turning. General functions, such as enhanced stock definition and rest material display, or the job-list-based adaptation of tool paths, simplify daily work. Highlights like intelligent macros, new 5axis shape offset machining and the hyperMILL® API offer several new ways to program and manufacture more efficiently.

Automation based on intelligent macros, API and CPF

hyperMILL® can organize even highly complex machining steps with predefined rules and conditions using intelligent macros. These powerful macros quickly generate complete, process-optimised program parts while also considering the model, materials, cutters and other parameters.

Application programming interfaces are also well suited to automating recurring processes. APIs are therefore used to create applications that control the generation of machining programs. Due to modern .NET-technology all established programming languages like Visual Basic, C# or C++ can be used with the hyperMILL® API.

The Customised Process Features enable companies to define individual corporate standards for automated programming by linking characteristic geometry sequences with freely definable machining steps. The automatic selection script helps users to choose any combination of criteria with limited or no selections on the part model.

5axis shape offset roughing and finishing

Surfaces with uniform offset can now be machined using 5axis milling while avoiding the formation of steps. The new machining strategy in hyperMILL® simply turns the arched surface into the standard surface, allowing the tool to work normal to the surface. The ultimate process then produces results that are like a “curved Z-level” roughing or finish, and efficiently machines the surface with little remaining rest material.

As the tool is placed normal to the hub surface, there are hardly any undercuts. The tool angle is calculated for machining either from the hub surfaces of the model or from an externally-designed guide surface.

The tool paths calculated on the basis of this strategy ensure optimal results, for example, in connection with rounded inner corners and automated approach and retract macros in finishing work.

64-bit support for further time savings

64-bit support means that users have more memory at their disposal. This is especially useful when programming large parts, and on computers with multiple processing cores.

For more information, visit:

Thursday, 25 August 2011 11:35

Autodesk certifies the hyperMILL® CAM solution

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OPEN MIND Technologies AG announces that the hyperMILL® CAM solution is now certified for Autodesk Inventor 2012 mechanical design and engineering software. This officially confirms the seamless integration of hyperMILL® into the latest release from the leading provider of Digital Prototyping solutions. Digital Prototyping with Autodesk Inventor software gives manufacturers the ability to digitally design, visualize and simulate how a product will work under real world conditions before it is built, which helps reduce cost and increase efficiency. Data associativity enables continuous processes when the two systems are combined.

The hyperMILL® CAM solution from OPEN MIND and its wide range of machining strategies and optimisation functions underwent rigorous test procedures at Autodesk. The current version of the software has now been certified as meeting the highest standards of quality and compatibility and has been successfully integrated into Autodesk Inventor 2012. Thanks to full associativity with Autodesk design data, it is now possible to have CAM operations automatically updated in hyperMILL® if changes are made to the CAD models. Sharing access to the same database and using hyperMILL® from the CAD user interface increases speed and efficiency, helps prevent errors and reduces the user’s overall workload.

“The Autodesk Inventor certification confirms the interoperability of a product. The integration offers the user efficient processes, transparency and precision throughout all manufacturing steps, while also ensuring the highest possible accuracy,” explains Carl White, director of Inventor digital design product management at Autodesk.

The Autodesk Inventor software suite offers professional solutions, from 2D and 3D right through to digital prototyping, in order to digitally design, visualise and simulate products before they are manufactured. The integration of hyperMILL® allows users to directly access the optimal machining strategy for their product in a continuous workflow using the familiar user interface for the CAD application. This ensures a seamless process from design through to manufacturing.

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The CAM company OPEN MIND continues on course for growth. The company from the ‘Mensch und Maschine’ Group (MuM) can look back on a positive 2010, which saw not only sales and employee numbers increase but also the company’s global presence. Management has also identified bright prospects for continued success in 2011. The company recorded sales amounting to EUR 10.3 million in the first quarter of 2011, which represents an increase of 9.2 per cent on the same period last year.

According to the ‘NC Software and Services Market Assessment Report’ by CIMdata, OPEN MIND was the only leading CAM software company to continue to grow in the crisis year of 2009. The company’s sales grew even further in 2010. Direct sales for 2010 were increased to EUR 27 million, which represents a growth of approximately 20 per cent relative to 2009. Its presence in regional markets was also further expanded. The company currently employs 180 people and now has 13 subsidiaries all over the world, including the newly founded branches in Sweden and Spain.

“The figures prove that we are on the right track,” explains Volker Nesenhöner, CEO of OPEN MIND Technologies AG. “I am proud of our qualified and highly motivated employees. Together, we succeeded in inspiring users of NC machines in a wide variety of sectors to opt for our CAM software solutions thanks to our innovative technologies.”

Dipl-Ing. Volker Nesenhöner is the new CEO as of February 2011. Dr Josef Koch was appointed to the Executive Board as the Executive Director of Technology. Markus Pech will remain the CFO and will continue to represent the MuM Group. The Executive Board has named a direct sales target of EUR 30 million and believes the company is on track to meet this target, having generated EUR 10.3 million in the first quarter of 2011.

For more information, visit:

OPEN MIND Technologies AG is now offering a 64-bit version of its CAM solution hyperMILL® for integration into the Autodesk® Inventor® and SolidWorks® CAD platforms. This enables the latest workstations to be used with 64-bit processor architecture from the design phase right through to CNC manufacturing.

In the past, large detailed components proved a challenge for CAD and CAM systems, with calculations pushing the capacities of the computer hardware to its limits. The introduction of 64-bit architecture allows more than 4 GB of RAM to be targeted directly. The CAM solutions hyperMILL® in Autodesk® Inventor® and hyperMILL® for SolidWorks® take full advantage of this option to use extended memory and more efficient multi-core processors. Models that require numerous job steps and multiple tool paths to be machined can now be calculated at a significantly faster rate. Now, users of these integrated versions of hyperMILL® will no longer have to deal with restrictions imposed by computer hardware and can instead take advantage of improved performance during their daily work.

The continuous workflow from development to manufacturing with Autodesk® Inventor® and hyperMILL® was awarded Autodesk® Inventor® certification. Dassault Systèmes SolidWorks Corp. has also certified hyperMILL® and has named hyperMILL® for SolidWorks® a Certified Gold Product.

Additional information is available upon request or from our website at:

Winning races, whether bikes, trucks, or Formula One, involves much hard work and effort from a variety of sources. There’s the engineering and construction of the vehicle and all its components (engine, frame, tires). Track conditions, fuel strategies, pit performance, and many other variables all play a part. At the heart of it all, though, is a driver and the driver’s will to win.

Todd Cuffaro is a driver, formerly of race cars and now, as president of Miller CNC, based in San Diego, California, he is driving his company to finish first in a number of areas, mainly performance on complex parts, quality, turnaround time, and sales.

“We’ve been in business part-time since 2007 and went full-time in mid-2009 when we began getting out of racing,” Cuffaro explains. A dirt bike racer as a kid, Cuffaro, 26, had grown into spending half his time racing and half running a race car prep business. “My uncle, a lifelong hobby machinist (and the Miller of Miller CNC), left his job to launch his own shop,” Cuffaro says. “We partnered up, bought some equipment (lathe, mill and other necessary tools), and started learning the machining business.”

Just at the time Cuffaro was getting experience on some pretty trick race car parts, such as brake hub assemblies and other steel and aluminium parts, his uncle injured his back and had to return to his former job. Cuffaro faced a fork in the road. “Through racing, we were able to store a little money away,” he says. “We were getting busier as a shop and made the decision to sell of our racing equipment and go full-bore as a machine shop. Part of that decision was to go CNC and high quality from the start, which for us meant 5-axis machining.  That’s where we dedicated the majority of our attention.”

The centerpiece of the shop is a Hermle C30U five-axis CNC machining center with a working area of 650 mm in X, 600 mm in Y, and 500 mm in Z, an NC-controlled swivelling rotary table, and a 32-tool magazine. Other equipment includes three Haas vertical machining centers with 4th- and 5th-axis capability, a Haas CNC turning center, two Hwacheon CNC lathes, and a Brown and Sharpe CMM.

The young company began casting its nets for more business, billing itself as a quick-turn, high-tech job shop for competitive service on complicated parts. “Our philosophy is really simple,” says Cuffaro. “Give 110% no matter what. We’re a young business and we simply transferred our competitive spirit from racing into the machine shop. We’re eager to take on difficult parts and challenge ourselves. With our 5-axis capabilities and the software we’re running, we can be very competitive with most types of milled parts, not just true 5-axis parts. If the part has more than two ops on a vertical, we throw it on a dovetail fixture in the 5-axis mill and handle it in a single setup. Accuracy is much better, part handling is reduced, and we maintain short lead times, which we’ve found is a huge advantage in a slow overall economy.”

CAM Just As Critical As Equipment

As Cuffaro and his team were investigating 5-axis equipment in earnest, it became apparent to them that the CAM system running the machine was as important as the machine itself. “If the two can’t work in unison, you’ve got a huge mess on your hands, spending too much time working around problems to be competitive,” explains Cuffaro. “We needed to be able to create fixtures and toolpaths without too much wasted motion. We also wanted flawless machining simulation with the goal of eliminating setup time and running 100% on the first part.”

After kicking the tires on a number of popular CAM systems, Miller CNC purchased the Hermle machining center and a seat of hyperMILL from OPEN MIND (headquartered in Wessling, Germany, with US operations in Needham, MA, and support offices throughout the U.S.) at the same time. “We were counting on the personal service we were promised after the sale,” Cuffaro relates. “We were taking some really big steps in a really short amount of time, and I wanted to avoid any disruptions that would result in moving backward as opposed to the huge leap forward we wanted.”

Training on hyperMILL involved a week of one-on-one at Miller CNC, after which the company was confident in making parts on its own. “hyperMILL turned out to have everything we knew we needed plus several features we didn’t appreciate prior to implementation, like stock regeneration and feature recognition,” Cuffaro says. “We’re able to import a 3D model, design a fixture, create efficient toolpaths, simulate the machining process, and post the code to the machine, all in the same program. Any rev change, we just regenerate the solid model and the toolpaths adjust themselves”

From Hours to Seconds

Feature recognition played a role in helping Miller CNC tackle an amplifier box aerospace part with 600-plus holes. Where the shop had to pick every hole and program for center drilling, drilling, tapping, hole depth, and inclination, machining specialists at OPEN MIND were able to show Miller’s programmers how to build a macro that would communicate the entire job to the machine tool in a fraction of the time. With feature recognition, existing CAD geometry information is used for CAM programming, and typical and repeating geometries are defined as features. Along with the assigned geometries, features contain all information relevant to production, such as top, bottom, and start point. These are defined once and can then be assigned to the machining strategy.

“From a single programmed coordinate system, the software automatically defines the hole type, depth, and inclination using feature recognition and applies machining parameters with macros based upon the customer‘s shop standards,“ says OPEN MIND Account Manager Kevin Lewis. The movement between positions, including jumping over bosses, is 5-axis movement collision-checked against the model. “Collision checked removal of Safe position movements save time,“ Lewis adds. “The result is production machining without the hassle.“

More importantly, programming the job and communicating all the information to the machine tool is now a matter of 20 seconds versus the three hours it previously took.

Cuffaro also credits hyperMILL programming with landing and keeping a complex medical part – a prosthetic weightlifting device from San Diego-based mechanical design firm Luxon Engineering. “It’s an assembly that clamps around a barbell or dumbell so an amputee can safely lift weights and stay in shape,“ he says. “The parts are fairly complicated and require tight tolerances to make sure the assembly mates together perfectly. The first run was on our three-axis vertical using another CAM system. We completed the part in five operations and needed a custom tool and some fixturing. It definitely took too long. Another order came right as we were implementing the new 5-axis machine and hyperMILL, so we decided to throw the old process out the window and start over. We used the solid model of the part, mated it to our vise, and programmed the part as an assembly so that there was no chance of a tool collision. It was the first part we did on our own with the hyperMILL programming. It didn’t take long at all and we completed the part in two operations. Since we’re creating toolpaths directly off the surfaces of a solid model, and the model regenerates after each cut, there are very few wasted movements.“

Cuffaro also credits the fact that OPEN MIND has actual machinists among its support personnel. “They actually understand machining in addition to the software, so they’re really helpful. They can walk us through our part to answer the actual question and still show us several different ways to handle the task. The software has so many options as far as toolpaths or machining strategies that it helps sometimes to have a guiding hand point you in the right direction.“

According to the customer, part quality was significantly improved and the part was completed much more quickly without the need for custom fixturing, Throughout the process of implementing hyperMILL, Cuffaro says he’s learned how valuable the right tools can actually be. “We make several different aluminum housings with intricate pockets and up to a few hundred tapped holes,“ he says. “Previously, we were forced to constantly create our own geometery to make sure we weren’t slamming end mills into corners, and we had to pick hole locations one by one. Now we can use feature recognition and tell hyperMILL to use a half-inch end mill for roughing these pockets, a quarter-inch end mill for finishing, and then drill/tap all the 2-56 holes on X level. With macros, every time we’re doing a common feature, we use the same tools, and feeds and speeds are already proven. Programming is faster by a significant amount, we aren’t breaking tools during setup, which would force us back into editing the program, and our cycle time is quicker. The burden rate is slightly more, but hyperMILL is so much faster that it instantly creates a return. Jobs are more profitable and we have more machine time available.“

Cuffaro says the cutting edge capabilities of Miller CNC (the company recently completed ISO 9001 and AS-9100 certifications) have him predicting sales will double in each of the next three years. He also believes his process advantages can help him exploit such situations as machining from a solid faster than waiting for castings. Automation and pallet systems are another area he’s investigating. “We want to put out what customers want to see in a shop: quality, process efficiency, quick turnaround, and competitive pricing. We always have to be doing something different.“

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OPEN MIND Technologies AG has released its new hyperMAXX® optimisation strategy for stock roughing within hyperMILL® 2010. hyperMAXX® is powered by Celeritive Technologies’ VoluMill™ toolpath layout engine. The high-performance roughing module, which is fully integrated in hyperMILL®, combines optimal milling paths and maximum material removal with minimised machining times. In particular, features like the constant radial depth of cut and fully automated dynamic feedrate and infeed adjustment facilitate fast and gentle milling and provide the basis for perfect cutting conditions.

The new optional hyperMAXX® high-performance roughing module generates ideally distributed 3D milling paths. hyperMAXX® removes large volumes of material efficiently and reliably, reducing the wear and tear of both milling machine and cutting tools. This is achieved by establishing and maintaining ideal cutting conditions throughout, regardless of the shape of the part. Milling parameters are set based on best-case scenarios, rather than according to the usual “worst-case” situations like cornering, entry moves and connection paths. Feedrates are also adjusted dynamically in special machining conditions to ensure constant volume removal. Roughing time savings of 50% or more are typical.

Moreover, as the new strategy is fully integrated in hyperMILL®, there is no need to open any additional software tools, change the program or adjust the post-processor. hyperMAXX® toolpath layout optimally complements the other roughing strategies in hyperMILL®. The Celeritive VoluMill toolpath kernel has been successfully used in the market for years within standalone versions and other integrations. This is matched with proven hyperMILL® analysis for slicing, stock management, collision detection and more.

hyperMAXX® increases the machine’s service life and reduces milling times. As hyperMAXX® performs all machining jobs in a predictable, consistent manner, the tools and machine are subjected to an even load, resulting in an increased service life. The tool paths are completely free of abrupt changes of direction and other extreme tool movements, thus providing the basis for a high surface quality. hyperMAXX® ensures maximum material removal and the fastest possible safe positioning of the tool, resulting in reduced machining times and more efficient production.

Intelligent, flexible, user friendly. The high performance of hyperMAXX® is made possible by intelligent automated functions, such as a feature that accounts for the material and dynamically optimises both the feedrate and infeed during 3D arbitrary stock roughing to control the volume of cut. This option is seamlessly integrated with hyperMILL’s roughing procedure to simplify learning and implementation. There are also two selectable functions: The first‚ “opening cut”, is suited for full-cut machining of areas that are difficult to reach, and is highly effective in softer materials, such as aluminum. The “side cutting only” option enables opening via lateral infeed movements without full cutting, and is designed for machining harder materials. The plunge macro always creates a complete helix or ramp movement and automatically determines the helix radius. Up to 100 per cent of the tool diameter can be processed by infeed without any rest material remaining between adjacent paths.

Process reliability and broad range of applications. For axial infeeds, the process is absolutely reliable up to the maximum cutting length. hyperMAXX® is suited for machining soft as well as hard materials that are hard to chip, such as titanium, nickel-based alloys or stainless steel. Both machining large parts and performing micro jobs can be handled quickly and efficiently using hyperMAXX®. The function range of the high-performance roughing strategy also includes a collision check that accounts for tool lengths as well as plane detection in automatic mode. In addition, the residual geometry can be defined as a stock for subsequent job steps. OPEN MIND Technologies USA Managing Director, Alan Levine says “It is very interesting to watch experienced manufacturing professionals’ positive reactions to the performance of hyperMAXX® during successful test cuts.”

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