Zeltwanger Maschinenbau uses hyperMILL® from OPEN MIND
NC code simulation
05.11.2025 — As a leading service provider, Zeltwanger Maschinenbau GmbH specializes in complex high-quality component machining from the semiconductor, automotive, medical technology and micro-automation sectors. Utilizing CAD/CAM technologies hyperMILL® MAXX Machining, hyperMILL® TURNING Solutions and hyperMILL® VIRTUAL Machining, the company exploits the full potential of OPEN MIND software and also acts as a beta tester.
Zeltwanger's customers are demanding. For a company in the semiconductor industry that specializes in laser technology, the contract manufacturer supplies various components that all require the highest precision - from pin-sized stainless-steel parts to 250 kg workpieces machined from three-ton aluminum blocks. “µm tolerances are the order of the day for us,” says Wolfgang Pfeiffer, Head of CAM Programming at Zeltwanger Maschinenbau. “As the batch sizes range from one to series runs of around 500 units, we have to generate between 20 and 60 executable, reliable NC programs each week. To handle this workload, we program in two shifts and need CAM software that supports us, quickly and reliably.” Zeltwanger has been using hyperMILL® since 2008, and the CAM programming team of ten has expanded its capabilities with optional software modules such as TURNING Solutions and VIRTUAL Machining.
Accuracy assured
With hyperMILL® VIRTUAL Machining, the NC code can be reliably generated, optimized and simulated. This enables Zeltwanger to achieve maximum reliability in milling, turning and hybrid machining. Wolfgang Pfeiffer says: “The software only provides access to successfully tested and, therefore, safe, collision-free programs.”
Zeltwanger uses the software module intensively and is now a beta tester for hyperMILL® VIRTUAL Machining. This is particularly the case in the field of mill-turning, an area that OPEN MIND is continuing to expand in the use of virtual machines.
The NC codes for the 5-axis DMG Mori DMU125 µPrecision machining center are optimized in hyperMILL® VIRTUAL Machining and checked for collisions.
Turn-milling for cost-effective complete machining
Zeltwanger also utilizes turn-mill centers. Wolfgang Pfeiffer explains the advantages: “By combining turning and milling on a single machine, many parts can be completely machined in a single set-up. This eliminates downtimes when changing machines and prevents reclamping errors.” Programming turn-mill centers is one of the most demanding tasks, but hyperMILL® provided the answer with its TURNING Solutions and the TURN-MILL Machining module. “The turning functions are similar to milling for the most part, so that it was virtually self-explanatory for our experienced colleagues,” continues Wolfgang Pfeiffer. This provides the programmers with reliable toolpaths and a dependable simulation for these collision-prone machines. hyperMILL® offers the perfect tool for milling/turning centers with the MILL-TURN Machining module. The high-performance milling strategies can be combined with turning operations, allowing complete machining with efficiency, precision and safety.
Wolfgang Pfeiffer, Head of CAM Programming at Zeltwanger Maschinenbau