Swiss machining and AI-led automation transform CAM

Hexagon’s Manufacturing Intelligence Division has unveiled a major release of its Esprit Edge CAM software, addressing productivity and skills challenges with extensive user-friendly Swiss machining support and the first AI services powered by Hexagon’s cloud-based Nexus platform. 

For the first time, Esprit Edge introduces Swiss machining functionality, enabling safe, efficient and simplified programming for complex machines such as the Citizen L series and Star SR series. An intelligent digital twin acts as a precise virtual model of the machine, enabling advanced features like superimposition, composite axis control, and automatic prepositioning to optimise performance and ensure collision-free operations.

With tools for configuring collets, guide bushings and tool mounting blocks, Esprit Edge reduces user expertise requirements while making set-up faster and more consistent. Features such as automatic synchronisation, adaptive cycles and tilted plane rotation simplify programming for multi-channel operations, minimising manual coding and errors. 

Real-time simulation ensures safe and highly accurate, optimised machining, while high-quality, OEM-tailored G-code eliminates post-processor customisation. 

Leveraging AI to transform CAM programming with two new tools, Esprit Edge empowers manufacturers to automate repetitive tasks, reduce errors and improve overall efficiency, enabling faster time-to-market for their products.

Firstly, Hexagon Copilot, an AI-driven virtual assistant, provides 24/7 support for CAM programmers of all skill levels. With natural language processing, it offers tailored responses, expert guidance, and seamless integration into the software’s interface.

Secondly, ProPlanAI streamlines process planning and accelerates production. This self-learning automation tool uses historical machining data to predict and optimise processes for new parts, minimising manual intervention.

By combining Swiss machining capabilities with cutting-edge AI technologies, Esprit Edge now empowers manufacturers to overcome today’s challenges and prepare for the future of smart manufacturing.

More information https://hexagon.com/products/esprit-edge

Max Hilscher hits peak performance with Vericut

When things go smoothly, everything falls into place – Max Hilscher GmbH is a striking example of how the right digital strategy and tools can drive a complete cultural shift in manufacturing. This progressive automotive and aerospace supplier has, since last year, been relying not only on automated parts production, but also on a fully digital process chain with Vericut and Vericut Force from CGTech. The results? No more crashes, significant time savings, and a production team working with greater calm and confidence.

Parts ranging from single items to medium batches are machined on automated Hermle machining centres. For about a year, the company has relied on end-to-end process simulation with Vericut and feed rate optimisation using Vericut Force.

“A machine crash can easily cost five figures,” says Christoph Hilscher, who has managed the family business for 11 years. “And if you’re manufacturing complex milled parts for the automotive and aerospace industries, you simply can’t afford those kinds of mistakes.”

Machining at Hilscher is far from simple. With a focus on aluminium components, tolerances are tight, geometries are complex and batch sizes change frequently. The decision to use Vericut Force was made deliberately – not as a nice-to-have, but as a strategic necessity.

“We have to move with the times,” says machinist and lead CAM programmer Tobias Konrad. “Especially in single-part production, we need tools that help us machine faster and more economically – without sacrificing process security.”

Force delivers exactly that: realistic optimisation that achieves measurable time savings while reducing the strain on both tools and machines.

At Max Hilscher GmbH, the results speak for themselves. Depending on part geometry and material, machining time can be reduced by 5 to 40%.

More information www.vericut.com

Stratasys Launches GrabCAD Print Pro 2025

Stratasys has released GrabCAD Print Pro 2025, an important update to its print preparation software designed to reduce time, complexity and cost across additive manufacturing operations.

The software update includes full integration of Fixturemate, a design automation application developed by Trinckle to simplify fixture design. Fixturemate allows users to generate production-ready fixtures in minutes – no CAD experience required. With full integration of Fixturemate,  and enhanced features like 3D textures, void body creation and multi-session support, the new version gives users more control over part functionality and throughput while simplifying production workflows and reducing reliance on traditional engineering resources.

Manufacturers increasingly rely on additive manufacturing to improve agility on the factory floor, but many still face bottlenecks caused by fragmented software workflows and the need for skilled engineering labour. GrabCAD Print Pro 2025 shifts the work of fixture design from design engineers downstream to AM operators – enabling users of the software to create fixtures independently within GrabCAD Print Pro instead of using different CAD tools by different users with specialised design skills. Simplifying this process reduces creating new fixtures from days to hours.

“Before GrabCAD Print Pro 2025, even a simple fixture might take a day or more and require CAD skills and a manufacturing engineer,” says Jeff McGarry, managing partner at Automation Intelligence. “With GrabCAD Print Pro 2025 and Fixturemate, we’ve dramatically accelerated our design workflow, turning concepts into printable CAD models faster than ever before.”

Adds Victor Gerdes, vice president of software at Stratasys: “GrabCAD Print Pro 2025 reflects our platform approach to AM – focused on eliminating workflow barriers while expanding material and printer support.”

More information www.bit.ly/46p2cJM

KS Composites on fast track with hyperMILL

Imbued in the motorsport industry since Kelvin Smith opened the doors for business in 1985, KS Composites is a manufacturer with a pedigree of working with numerous Formula 1, GT, Le Mans and BTCC teams. Throughout its history, the Melton Mowbray-based company has worked at the very pinnacle of motorsport – and that is why KS Composites has invested in CADCAM software from Open Mind Technologies.

Having formed many close relationships with some of the leading lights in design and consultancy through prototype and development projects, KS Composites offers design services, FEA and CFD. This is complemented by a 48,000 sq ft manufacturing site that supports the design and consultancy services with everything from kit cutting, fitting and assembly to wet lay composites, autoclaves and ovens, a composite shop, machine shop and much more.

Looking at a replica race car the company has manufactured, business development manager Dan Johnston says: “On the vehicle itself we have carbon composite body panels and machined GRP and 3D printed elements. We’re hitting on all our core services with this vehicle. One of the first things to come into our new building was CNC machines. At that point, we identified that we needed a CAM package that could get the most out of our machines. We went to the market and evaluated the options, and it was clear from the offset that hyperMILL was the obvious choice.”

He adds: “hyperMILL is making our life so much easier, especially when making things like a show vehicle. We’re representing motorsport’s pinnacle in terms of performance and precision. So, when making the patterns, they had to be of the same quality – that’s what we have achieved with hyperMILL.” 

More information www.openmind-tech.com

PTC launches Arena to mitigate supply chain risks

PTC has announced the release of its Arena product lifecycle management (PLM) and quality management system (QMS) solution that will provide manufacturing and product developers with greater supply chain security.

Arena Supply Chain Intelligence continuously checks for emerging risks from evolving economic conditions and eliminates the need for disconnected supply chain tools by embedding real-time, AI-driven component monitoring and risk mitigation insight directly into product development workflows.

These capabilities transform how product development teams manage component issues throughout the entire product lifecycle within the existing PLM environment. Companies can use Arena SCI to monitor components continuously across bills of materials to identify emerging and changing supply chain conditions.

When risks are detected, the platform provides visibility, suggests alternative components based on technical compatibility and enables teams to make more informed sourcing decisions earlier in the product development process – helping prevent future sourcing interruptions before they impact production.

“By delivering supply chain intelligence directly where design decisions are made in a cloud-native environment, Arena Supply Chain Intelligence simplifies collaboration between design teams and suppliers and supports more proactive component sourcing decisions,” says David Katzman, PTC’s general manager of Arena and Onshape. “Supply chain collaboration has been one of Arena’s core strengths for years, and our investment in SCI adds a new dimension for our customers as they prioritise resiliency. We expect to enhance SCI with even more features in future releases, including more AI-driven functionality powered by Arena AI.”

PTC says Arena’s cloud-native PLM and QMS solutions are the trusted source for product development, quality management and multi-tiered supply chain collaboration at nearly 1500 global manufacturers.

More information www.bit.ly/484cTTg