OPEN MIND

Key Takeaway

hyperMILL® CAD/CAM technology for next-generation manufacturing in the aerospace industry

From complex geometries to difficult-to-machine materials – the special requirements of the Aerospace industry demand maximum precision, efficiency, and process reliability. hyperMILL® combines proven partnerships, innovative CAM strategies, and state-of-the-art automation to reliably manufacture components for the next generation of aerospace technology in a future-proof manner.

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The CAM software you can trust

Global presence. Measurable aerospace expertise.

  • 800+ customers: OEMs, Tier Suppliers and MRO Companies
  • Presence in 24 key regions;
  • Aircraft, helicopters, rockets, eVTOLs, drones, satellites
  • From earth to space – hyperMILL® is part of the mission

Research and industry partnerships – trust through strong networks

hyperMILL® is closely linked to international aerospace research and collaborates with renowned institutes around the world. These collaborations ensure access to the latest manufacturing methods and validated processes. At the same time, OPEN MIND maintains close partnerships with leading machine and tool manufacturers in order to optimally tailor machining strategies to the material, tool, and machine. The result is consistently validated processes that guarantee users in aerospace manufacturing the highest precision, maximum efficiency, and absolute process reliability.

The five key challenges facing aerospace manufacturing

The aerospace industry is under enormous pressure to innovate and reduce costs. OEMs and tier suppliers must reliably manufacture highly complex components, comply with the strictest quality standards, and integrate new technologies at the same time.

hyperMILL® supports companies in efficiently mastering these challenges with reliable, certifiable CAM strategies that secure a decisive competitive advantage.

Complex Geometry

Components such as blisks, impellers, and thin-walled structural parts require sophisticated CAM strategies. hyperMILL® offers a variety of powerful strategies, including specialized 5-axis strategies for maximum precision and surface quality.

Difficult-to-machine materials

Titanium, Inconel, superalloys, and composites increase tool wear and costs. Optimized strategies and High-Performance Cutting (HPC) significantly reduce machining time and tool wear.

Efficiency and cost pressure

Long machining and programming times reduce added value. State-of-the-art automation, feature and macro technology, and high-performance methods reduce effort and throughput times.

Safety and quality requirements

Zero-error tolerance and process-reliable NC programs are mandatory. hyperMILL® delivers audit-proof NC programs and verifies them in its own NC code simulation, hyperMILL® VIRTUAL Machining. In addition, connectivity with the machine ensures a standard-compliant approval process for NC programs.

Technological change and innovation

eVTOLs, hybrid manufacturing, and sustainability goals are changing production. At the same time, new start-ups with innovative concepts are bringing additional momentum to the industry. hyperMILL® is flexible and scalable—ideal for additive, adaptive, and hybrid manufacturing concepts in a dynamic aerospace environment.

 

Two worlds, one technology: aviation and space

The Aerospace industry has a wide range of requirements – from the efficient machining of large-volume structural components to the high-precision manufacturing of tiny space components. That is why we divide the industry into two main areas:

Aviation

Aviation

Space

Space

Why hyperMILL® is the key to efficient and reliable aerospace manufacturing.

Whether it's civil aviation with complex structural, engine, and landing gear components or space travel with satellites, launch vehicles, and new space applications, both areas place extreme demands on precision, process reliability, and efficiency. hyperMILL® offers exceptional flexibility in toolpath generation: even the most demanding materials such as titanium, Inconel, other superalloys, or composites can be machined with process reliability because tool movements are perfectly adapted to the respective machining conditions. This adaptability makes hyperMILL® the ideal solution for aerospace manufacturing at the highest level.

Security and trust – made in Germany

hyperMILL® stands for quality and data security tested to the highest standards. With the German on-premises solution, all design and manufacturing data remains entirely with the customer – protected from unauthorized access and compliant with national and international guidelines, such as US ITAR regulations. Developed in Germany, hyperMILL® meets all European data protection and security requirements – for maximum control, compliance, and trust in safety-critical industries such as aerospace.

More videos

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hyperMILL® 5-axis Machining: Connecting Plate
hyperMILL® TURN-MILL Machining: Aerospace Housing
hyperMILL® 5-axis Machining: Air Baffle
hyperMILL® 5-axis Machining: Connecting Plate

This demo part reflects typical aerospace structural characteristics and was machined on a Hermle C42 from EN AW-7075 aluminum. The process combines high-performance roughing and finishing operations, ensuring maximum efficiency and accuracy.
Circle segment cutters were used to maximize finishing performance on the thin-walled areas.

hyperMILL® TURN-MILL Machining: Aerospace Housing

This aerospace-inspired aluminum housing showcases the latest multitasking machining functions on a Mazak Integrex i-100HS – combining advanced turning and milling strategies, HPC turning, and circle segment cutters for perfect finishing.
See how hyperMILL®s CAM strategies deliver precision, efficiency, and process reliability in one seamless workflow.

hyperMILL® 5-axis Machining: Air Baffle

This aerospace-inspired part was machined from 1.2738 steel on a GF Mikron MILL P800 U. Programmed with hyperMILL® and the hyperMILL® MAXX Machining performance package, the roughing process combines HPC machining and form-offset roughing for maximum material removal efficiency. Circle segment cutters were used to achieve outstanding surface quality and precision.

 
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