Verify and Optimise NC Programs Faster with Latest NCSIMUL 

Hexagon’s Production Software Division has introduced the latest release of NCSIMUL, strengthening its integrated approach to NC program verification, simulation and optimisation with new ‘Selective Simulation’ capability. 

NCSIMUL combines G-code verification, CNC simulation and optimisation within a digital-twin environment, helping manufacturers check NC programs, improve machining efficiency and reduce the need to prove out complex work on valuable machine tools. 

Selective Simulation provides programmers with a faster way to navigate long, complex NC programs. The patent-pending capability uses GPU-accelerated ‘Rest Stock Previews’ to generate intermediate stock models during NC decoding, providing earlier visibility of how a part develops throughout the machining process. 

The potential time savings were demonstrated in a customer trial involving an American athletic footwear manufacturer and a long-cycle mould application. A program with a 47-hour machine run time previously required 48 minutes of sequential simulation before the programmer could inspect the required operation. Using Selective Simulation, Rest Stock Previews were generated in under two minutes. 

Programmers can use these previews to inspect the part at different stages, identify potential issues earlier and move directly to operations requiring closer attention. Full NC code simulation, including complete collision detection and accurate material removal, remains the standard for final verification before releasing a program to the machine. 

“Selective Simulation gives programmers a more flexible way to work through complex programs,” says Jasper Sanders, product manager for NCSIMUL at Hexagon’s Production Software Division. “They can gain useful visibility much earlier, focus their attention on the operations that matter most, and still rely on the full NCSIMUL simulation engine for final verification.” 

Ultimately, the latest release helps manufacturers make better use of engineering time and machine capacity while maintaining confidence in NC programs before production begins. 

More information www.hexagon.com/products/ncsimul 

Vericut 9.7 Offers CNC Shops Performance without Compromise

Vericut has released the latest version (9.7) of its CNC simulation, verification and optimisation software, delivering faster simulation, expanded AI assistance and smarter workflows while retaining machine-level accuracy. 

Designed for manufacturers handling increasingly complex NC programs, machine configurations and demanding production schedules, Vericut 9.7 introduces performance improvements across simulation, verification and review workflows. These include faster processing of complex NC programs, improved handling of advanced machine configurations and toolpaths, and optimised workflows that reduce set-up and review times. 

The software continues to provide realistic CNC simulation, enabling manufacturers to detect collisions, verify G-code, review machine motion and optimise machining processes before programs reach the shop floor. This capability is particularly valuable for complex five-axis machining, high-value materials and advanced machine configurations where confidence is critical. 

Version 9.7 also expands Vericut Assistant, its AI-powered guidance tool. Users can access context-aware answers and Vericut knowledge directly within the software, reducing the time spent searching manuals and helping programmers and engineers navigate advanced workflows more efficiently. 

Alongside the release, Icam Post V27 introduces new tools for developing, testing and maintaining post-processors. Its new Vericut Icam Post AI Assistant provides access to official Icam Post documentation within QUEST and GENER, helping users find answers, check macro syntax and access product guidance without leaving their workflow. 

A new ‘Regression Testing Utility’ allows developers to compare NC output before and after post-processor changes, identify machine-impacting differences and validate updates before deployment. Other enhancements include improved debugging through ‘Breakpoint Manager’ and ‘Macro Manager’, greater kinematics visibility, and advanced SmartPATH motion control. 

Vericut 9.7 also introduces ‘Tool Manager’ enhancements for more efficient tooling organisation and improved visibility of tooling data, helping manufacturers manage increasingly complex machining environments with greater confidence. 

More information www.vericut.com 

KASTO Introduces New Control Generation for Sawing Machines

Sawing machine and storage system manufacturer KASTO has introduced a new generation of controls for its sawing machines, combining modern operating principles with practical features to help both experienced and first-time users operate quickly, safely and productively. Initially implemented on the KASTOwin bandsaw series, the new control will undergo subsequent expansion to other models. 

An optimised software architecture provides faster programme loading, quicker response to operator inputs and increased machine availability. At its core is a clearly structured dashboard displaying key information including runtimes, downtimes, current orders and machine status. Operators can rearrange job orders and switch between views, while simultaneously displayed function windows and context-sensitive help reduce clicks and speed operation. 

A ‘Simple Mode’ presents only essential information, guiding novice users safely through the sawing process. User-specific access ensures operators, supervisors and maintenance personnel see information relevant to their roles, while individual settings such as language, measurement units and preferred analytics can simplify training. 

A preloaded material library links material profiles with cutting feeds and speeds, while previously entered data is retrievable to reduce job-entry times. Cutting plans enable the quick creation of multiple jobs with different cut lengths, with each plan assigned to a specific order for better organisation and traceability. 

Used with KASTO’s OptiSaw Light software module, the system automatically assigns orders to available bars, optimising cut sequence and placement to minimise material waste and maximise utilisation. 

A new cycle-stop function allows users to pause and resume jobs from the exact interruption point without re-entering data. Comprehensive diagnostics also identify whether faults are mechanical or electrical, and whether they originate from the machine or material handling system. Analysis functions provide visibility of run time, downtime and saw-band condition. 

More information www.kasto.com 

CAMIO 2026 Launches with Renishaw REVO Five-Axis Integration

LK Metrology has unveiled a major release of its proprietary CAMIO software for programming, analysis and reporting on co-ordinate measuring machines (CMMs). CAMIO 2026 R1 advances multi-sensor metrology with comprehensive support for Renishaw’s REVO five-axis scanning probe system. 

The development enables manufacturers to combine REVO’s synchronised five-axis motion with CAMIO’s advanced inspection capabilities for complex measurement tasks. Users can program and execute REVO inspection routines directly within CAMIO, including advanced strategies such as sweep scanning and head touches. 

CAMIO optimises probe motion and measurement paths to reduce inspection times while maintaining accuracy. Its intuitive interface and offline programming capabilities also allow the creation, verification and optimisation of inspection routines before deployment on the CMM, helping improve productivity and minimise machine downtime. 

“We always strive to give manufacturers the freedom to choose the right metrology hardware for every application, without changing the way they program and inspect parts,” says Jonathan Rich, CAMIO product manager. “Support for the REVO five-axis system is another important step in delivering an open metrology platform that adapts to the user’s manufacturing environment.” 

CAMIO’s plug-and-play interoperability with REVO-equipped CMMs also allows manufacturers to use a single inspection software platform across mixed-brand machines, providing a consistent programming and inspection environment while reducing software lock-in. 

Compatibility with REVO-equipped CMMs is achieved using the industry-standard I++/DME client/server architecture. CAMIO operates as the I++ client, communicating with the UCC controller’s I++ server over a standard TCP/IP network. This standards-based approach avoids proprietary software or hardware modifications, simplifying integration while allowing manufacturers to maximise their existing metrology infrastructure. 

More information www.lkmetrology.com

JWA CNC Precision Overcomes Complexity with Mastercam  

JWA CNC Precision is demonstrating how the right CAM technology can help manufacturers consistently and profitably manage complex components and demanding tolerances. The UK subcontractor produces around 2000 different components each year from a catalogue of 9000, with tolerances routinely reaching 5 µm. 

Working predominantly with non-ferrous materials, including aluminium, stainless steel, plastics and composites, Leicester-based JWA supplies one-off and medium-batch components for aerospace, defence and green energy applications.  

For more than 20 years, JWA has relied on Mastercam software as the foundation of its manufacturing infrastructure. Technical director Tim Shillabeer, who has extensive experience with multiple CAM platforms, says the software’s widespread use provides access to extensive knowledge and support, as well as training resources. 

However, JWA has gone beyond simply ‘using’ Mastercam. The company has developed standardised programming and set-up procedures that enable trained operators to move between jobs and machines with confidence. New employees can become proficient quickly, while annual refresher training helps maintain skills across the workforce. 

“As a long-time user of Mastercam, we’ve ironed out so many little nuances that work really well for us,” says Shillabeer. 

This standardisation has reduced machine downtime, shortened gaps between jobs, and eliminated hours lost through programming and set-up variations. It also enables JWA to respond rapidly to new manufacturing challenges using established libraries, defaults and processes. 

Describing the company as being “quite at the advanced end of the scale” in its use of Mastercam, managing director Pete Wood says the approach has helped JWA maintain demanding quality standards while scaling its operations. It has also supported the company’s achievement of AS9100 certification and created a flexible, skilled workforce capable of handling its diverse production requirements. 

More information www.mastercam.com