Simulation software hyperMILL® 2026

controldesignCAM

Overview
hyperMILL® 2026 delivers the next step in intelligent CAD/CAM programming, combining powerful automation with enhanced 5-axis and turning capabilities. New algorithms, optimized toolpaths and rest-material strategies, and improved orientation control simplify programming of complex multi-axis parts. Expanded VIRTUAL Machining simulation with digital twins increases process reliability before machining begins. Together with smarter job management and optimized workflows, hyperMILL® 2026 helps manufacturers program faster, machine more efficiently, and achieve higher precision and surface quality across demanding production environments.

Key highlights

• Powerful automation combined with enhanced 5-axis and turning capabilities
• New algorithms for optimized toolpaths and rest-material strategies
• Improved cutter orientation control and collision avoidance for multi-axis machining
• Expanded VIRTUAL Machining simulation and digital twin integration for process validation
• Smarter job management and workflow optimizations to reduce programming time

CAD — Selected new functions

• New clipping management: Centralized "Cut Views" tab to create, edit, delete, invert, rename and activate clipping planes; save settings as bookmarks for reproducible views.
• Variable Fillet: Create associative fillets with different start/end radii, options for Smooth and Invert to ensure clean tangents and easy subsequent editing.
• New shape: Cuboid: Quickly define rectangular geometries by center, edges, dimensions and orientation; optional creation as solid.
• Improved fillet and rounding behavior: Create radii without trimming surfaces; associative creation for later changes.

CAM — Selected new functions

• Sorting Job: Transform and rearrange complete machining sequences (multiple jobs and tools) while maintaining desired sequence logic; supports milling and drilling operations across tools.
• 2D Hale Machining: Specialized strategy for areas requiring high surface quality (e.g. sealing surfaces) with continuous tool-edge alignment; programming similar to 2D contour machining. (Currently available for Siemens controls; not included in maintenance.)
• 3D Automatic Rest Machining: Redesigned algorithms for Z level, Parallel and Normal strategies to detect and machine rest material areas more precisely with smoother overlaps and consistent feed behaviour.
• 5-axis Rest Machining: New calculation algorithms, improved cutter orientation (preference for fixed orientation), better collision avoidance and new "Minimum clearance angle" for enhanced tool control.
• 5-axis Automatic Mode: Automatic determination of optimal tool positions (indexed and simultaneous movements) with automatic orientation search and minimum clearance angle option; available across multiple 5-axis strategies (Rest Machining, Profile Finishing, ISO Machining, Rework).
• Optimized control of erosion paths (Electrode): Define feed (G1) or rapid (G0) segments selectively on eroding paths; control approach/departure movements and ensure correct 3D path output and simulation behaviour.

TURNING & VIRTUAL Machining

• hyperMILL TURNING: Extended support for complex turret configurations in VIRTUAL Machining, including mixed axial and radial station alignment, individual station tooling, realistic simulation and collision checking.
• CAM Plan Turning: Templates to enrich turning geometries automatically with manufacturing information; standardized, reusable turning contours for faster, more reliable turning and mill-turn programming.

TECHNOLOGY / Simulation

• hyperMILL® VIRTUAL Machining — Angle head support: Angle heads defined in TOOL Builder and fully considered in NC code generation, toolpath optimization, simulation and collision checking; supports Siemens (SINUMERIK 840D) and Heidenhain controls; automatic approach solutions for angle head machining.
• Expanded machine kinematics support including nutating heads and combined jobs with and without angle heads.

Tutorials & Webinars

• Curated video tutorials and a webinar with release highlights are available showing the most important new features of hyperMILL® 2026 and usage examples for manufacturing operations.

Brochure
Printable brochure "Version 2026 — What’s new" (pdf) describing the main enhancements and module overviews.

Caractéristiques / spécifications techniques

• Product name: hyperMILL® 2026
• Current release note: hyperMILL® 2026 | Update 1
• Primary domains: CAD, CAM, VIRTUAL Machining, TURNING
• Key modules / strategies: 5-axis Rest Machining, 5-axis Automatic Mode, 3D Automatic Rest Machining, Sorting Job, CAM Plan Turning, 2D Hale Machining, Electrode (eroding) optimizations
• Simulation: hyperMILL® VIRTUAL Machining with digital twin support and angle-head simulation
• Control / platform highlights: Explicit support noted for Siemens (SINUMERIK 840D) and Heidenhain in selected functions; angle head support and machine kinematics simulated in VIRTUAL Machining
• Documentation available: PDF brochure (What's new 2026)
• Notes: Some specialized functions (example: 2D Hale Machining, certain angle-head features) may not be included in standard maintenance and may be limited to specific controls or future updates.