Hexagon NCSIMUL 2025 is the latest flagship release of the premier CNC machining simulation and optimization software from Hexagon's Manufacturing Intelligence division. It is dedicated to verifying, optimizing, and monitoring CNC machine tool programs within a virtual environment to ensure safe, efficient, and error-free manufacturing processes.

Key Features & Capabilities

1. High-Fidelity Machining Simulation

   • Performs realistic 3D material removal simulation using a solid modeling kernel, accurately replicating milling, turning, mill-turn, multi-axis, and even additive manufacturing processes.

   • Detects critical potential errors such as collisions (between machine components, tools, fixtures, stock), gouges, air cuts, and axis travel limits.

2. Machine Digital Twin & Virtual Commissioning

   • Creates a true-to-life "digital twin" of the CNC machine based on its exact 3D model and control system for virtual dry runs before physical production.

   • Executes and validates G-code through a virtual post-processor, simulating the exact behavior on the target machine controller. This is essential for virtual commissioning and first-part verification.

3. Intelligent Program Optimization

   • Features the patented "Machine DNA" technology. It analyzes the dynamic performance of a specific machine (e.g., acceleration, jerk) to automatically optimize feed rates within the G-code, significantly reducing cycle times while maintaining quality and avoiding machine overload.

4. Process & Knowledge Management

   • Manages the complete digital workflow from CAD model and CAM programming through simulation to final shop floor execution.

   • Includes libraries for tools and fixtures and offers integration with PLM, ERP, and MES systems for connected data flow.