The Best of Both Worlds: A powerful solution for a hybrid manufacturing process

hyperMILL® is a power­ful solution for combining standard and generative machining in a single, hybrid manufacturing process. It features unique 5‑axis technology from OPEN MIND that is ideal for simultaneously controlling 5‑axis material deposition and thereby achieving optimal results.

hyperMILL® ADDITIVE Manufacturing provides a flexible strategy for direct material deposition. The Directed Energy Deposition (DED) process involves directly, selectively applying material to a component or platform. Both laser-based powder nozzle machining heads and wire arc additive manufacturing (WAAM) can be controlled during this process.

When additive and sub­tractive manufacturing are combined in a single machine tool, this is referred to as a hybrid manufacturing process. hyperMILL® enables users to perfectly program the cladding and the milling together. True-to-detail application and removal simulation as well as stock tracking between the individual machining steps guarantee the greatest possible process reliability.


  • Flexible strategy for additive material application
  • Variable filling strategies for planes as well as free-form shapes
  • 5‑axis simultaneous application with optimal tilt strategies
  • Full simulation of additive and sub­tractive processes, including material deposition
  • CAD interface to all common CAD systems
  • High level of laser configurability via technology parameters in the tool data­base
  • Hybrid stock tracking for all processes

The high deposition rates of the direct material application, combined with modern machining centers, enable a wide range of applications. Hybrid manufacturing is perfect for carrying out local, limited repairs on worn or damaged areas such as tooling or stamping die components or turbine blades and this within a short period of time. Moreover, composite metal structures can be manufacture by welding various ma­te­ri­als or via heat treatment with a laser. This new technology is highly significant, particularly in the field of tool and mold making as well as in the aero­space industry.

hyperMILL® by OPEN MIND offers the perfect solution for securely, continuously controlling all processes, from additive material application through to machining.

Continuous process flow

With hyperMILL® it is one continuous work­flow and all managed with­in one soft­ware.


Having a continuous process chain from material application to material removal is particularly de­ci­sive for hybrid systems. During the si­mu­la­ti­on, the material application is mapped and si­mul­ta­ne­ous­ly created across the entire si­mu­la­ti­on process. The major advantage is that milling can then be carried out directly on the app­li­ca­tion stock. Mean­while, additive and sub­tractive processes can be combined as desired and securely reviewed in the simulation.

Stock tracking

hyperMILL® calculates the corresponding stock for each additive or sub­tractive process and adds this to a stock chain. This stock is not only used for simulation purposes, but also for collision checks. This results in secure, precise mapping of the machining process.


Every technology manufacturer uses their own values and parameters for controlling the application. hyperMILL® provides a flexible solution that can be used to control individual parameters. Technology parameters can be defined and stored in the tool data­base. During the post­processor run, the cor­res­pon­ding NC code is then created together with all control commands for the respective machine.

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