Hexagon has announced new capabilities in Esprit Edge, designed to reduce CNC programming effort, improve process predictability, and help manufacturers manage increasingly complex machining environments.
As machine capability advances, the effort required to program and verify those machines continues to grow. The new features directly address that challenge. The first of four planned updates in 2026 introduces targeted enhancements across turning automation, Swiss-type machining, multi-axis toolpath generation, heavy machining, and cloud-connected workflows.
The latest release introduces ProPlanAI for turning, mill-turn, and Swiss programming, extending AI-assisted programming into a wider range of applications. By accounting for factors such as stock removal and previous machining strategies, it supports more accurate process definition while reducing manual input. This shortens programming time, reduces reliance on test cuts, and ensures proven machining strategies are applied more consistently across teams.
Support for multiple guide bushing configurations is now built directly into machine models, enabling programmers to switch between setups, including chucker-mode, without rebuilding machine definitions. This simplifies setup and increases flexibility when programming Swiss sliding-headstock machines.
Enhancements to collision detection in advanced three-axis turning introduce holder awareness, ensuring non-cutting elements are accounted for when tool orientation changes, whether through B-axis movement or Y-axis control. Developed with tooling partners, this improves confidence in toolpath safety in complex turning strategies, where tool orientation and engagement vary dynamically.
Updates to five-axis composite machining automate tool-motion generation, removing the need for external drive surfaces. This reduces preparation time and simplifies programming for complex geometries across production machining and mould and die applications.
A preview of new U-axis turning capability enables turning on milling machines by rotating the tool while the part remains stationary. A programmable linear axis controls diameter changes, extending capability for larger components and advanced machining scenarios. Pilot users are currently being engaged.
More consistent workflowsA redesigned cloud connector improves access to documentation, community resources, and software extensions, with clearer navigation between account management and application environments. This supports more consistent workflows across programming teams.
Updates to knowledge-based machining provide greater control over feed definitions in drilling cycles, improving compatibility across tooling strategies and reducing inconsistencies when applying non-drilling tools.
Olivier Thenoz, senior product manager, Hexagon Production Software Division, said: “Machine capability has moved ahead quickly, but the complexity of programming those machines, has increased just as fast. In high-value machining, the risk is not just inefficiency, it is whether a program will run exactly as intended. These updates are focused on reducing the effort required to prepare CNC programs that will run reliably, particularly in more complex, multi-axis and multi-channel machining environments.”
In high-precision R&D environments, where tolerances are measured in microns and designs change frequently,
Edwards Vacuum, a global provider of vacuum solutions for advanced industrial, turbomolecular, and semiconductor applications, part of the
Atlas Copco Group, relies on Esprit Edge to maintain control.
Wayne Turner, senior manufacturing engineer at Edwards Vacuum, said: “In our work, we are machining highly complex, one-off parts where designs change constantly, and precision is measured in microns. Esprit Edge allows us to adapt to those changes without starting from scratch, so what would otherwise take days of reprogramming can be recalculated in minutes.
“Crucially, it is the only CAM system we have found that can handle the full complexity of our mill-turn machines, including true multi-channel programming. There simply is not another solution that can do what we need at this level. When you are working with machines of this scale, the biggest risk is human error, and a single mistake can mean weeks of downtime and tens of thousands in cost.
“Esprit Edge gives us the confidence that what we program is exactly what will run, without introducing that risk. The high level of support we have received from Hexagon, particularly in developing a bespoke post-processor, has also been critical in making the system work exactly how we need it to.”