ESPRIT EDGE Release Highlights

Smarter automation. Greater machining confidence. Higher productivity.

As machine capability advances, the effort required to program and verify those machines continues to grow. Roughing strategies demand constant manual adjustment to hold consistent engagement. Calculated speeds and feeds can exceed what a machine can physically deliver. Complex geometries call for drive surfaces that take time to prepare. ESPRIT EDGE 2026.2 addresses these friction points directly, extending automation across roughing, speed and feed calculation, 5-axis programming and turning while improving overall stability across the platform.

Dynamic cutting optimisation

Maintaining consistent tool engagement across a roughing cycle usually means adjusting cutting conditions by hand, region by region. Variation in engagement leads to inconsistent chip load, uneven tool wear and unpredictable cycle times.

ESPRIT EDGE 2026.2 introduces dynamic cutting optimisation within the Pocketing cycle. When programmers apply ProfitMilling or Trochoid tool motion patterns, the software automatically adapts cutting conditions to the machining situation and holds engagement steady throughout the toolpath. Depth-Driven Optimisation extends this control to areas with varying cutting depths, adjusting radial stepovers automatically to keep the material removal rate consistent.

By holding engagement constant without manual intervention, programmers improve cutting stability and tool utilisation, shorten cycle times and produce more reliable toolpaths across the roughing operation.

Machine-aware speed and feed

A speed and feed calculation is only useful if the machine can execute it. When a calculated spindle speed exceeds the machine's maximum RPM, the program either fails to run as intended or forces the programmer back to manual correction.

ESPRIT EDGE 2026.2 improves machine awareness when programmers use KnowledgeBase Manager speed and feed data. The software now validates each calculated spindle speed against the machine's maximum RPM setting. When the calculated value exceeds that limit, ESPRIT EDGE adjusts it automatically and recalculates the feedrate to match.

This keeps machining strategies aligned with real machine capabilities, which protects tools, reduces the need for manual correction and delivers more consistent, predictable performance at the machine.

Enhanced 5-axis composite machining

Programming complex 5-axis geometry often depends on manually created drive surfaces. Building those surfaces takes time and introduces variation between programmers working on similar parts.

ESPRIT EDGE 2026.2 adds new FreeForm Part Driven patterns to Composite machining: the Contour Variable Offset pattern, the Open Flow pattern and the Central Pass Variable Offset pattern. These patterns automate more of the tool motion creation process and reduce the reliance on manually built drive surfaces.

For programmers working with complex parts, this means faster setup, more consistent toolpaths between team members and more efficient toolpath generation across production machining and mould and die applications.

Expanded turning capabilities

Larger components and advanced turning scenarios frequently reach beyond the range of a standard lathe setup, and verifying those operations takes time before production can begin.

ESPRIT EDGE 2026.2 extends turning capability with enhanced U-axis support, which enables turning on milling machines by rotating the tool while the part remains stationary. A programmable linear axis controls diameter changes, opening turning strategies to larger components and more demanding applications. Improved simulation for advanced turning operations gives programmers a clearer view of the process before any material is cut.

Together, these updates extend the range of parts manufacturers can produce on existing machines and let programmers verify demanding turning work with greater confidence.

Performance, quality and stability improvements

Verification time and platform reliability shape day-to-day productivity as much as any single machining feature.

ESPRIT EDGE 2026.2 improves simulation performance for certain helical milling operations, delivering up to 2.4 times faster simulation, around a 40 per cent reduction in workpiece facet count and improved memory efficiency. This release also includes a range of quality enhancements, performance optimisations and issue resolutions across the platform.

The result is less time spent waiting during verification and a more stable, predictable environment for programmers working on demanding projects.

Upgrade to ESPRIT EDGE 2026.2

Manufacturers running current ESPRIT EDGE licences can access these capabilities through a standard update. Upgrading applies the latest automation, machine awareness and stability improvements across roughing, 5-axis programming and turning, helping programming teams reduce manual effort and produce programs that run as intended.

Contact your ESPRIT EDGE representative or visit the Hexagon Customer Portal to upgrade.

Advancing Automation, Flexibility, and Machining Performance

ESPRIT EDGE 2026.1 delivers advancements in turning automation, multi-axis machining, heavy machining innovation, and cloud connectivity. This update continues to strengthen ESPRIT EDGE as a next-generation CAM platform, modernising programming workflows across turning, Swiss-type, mill-turn, and 5-axis environments.

ProPlanAI for Turning, Mill-Turn & Swiss

AI-driven automation, now extended to turning.

ProPlanAI is now commercially available for turning, mill-turn, and Swiss programming, bringing automation to a wider range of machining processes. With enhanced process prediction that considers stock removal, it delivers more accurate and reliable toolpaths.

A new prediction feedback interface improves visibility, while the system continuously learns from historical shop data, capturing expertise and enabling consistent, automated programming across teams.

Swiss Guide Bushing Configuration

Greater flexibility for Swiss machining setups.

Built-in support for multiple guide bushing configurations allows users to easily switch between standard setups and chucker-mode operation. All configurations are managed within a single machine model.

This simplifies machine development and maintenance while enabling programmers to adapt quickly to different part requirements and production scenarios.

Advanced Turning Collision Detection

Safer toolpaths with enhanced collision awareness.

Collision detection has been significantly improved with holder-awareness, ensuring non-cutting parts of the tool are fully considered during roughing with variable orientations.

Developed in collaboration with Tooling leaders, this enhancement increases confidence in toolpath safety, especially when working with advanced turning tools and complex machining conditions.

5-Axis Composite Machining – Modernized

Simpler workflows for complex geometries.

The 5-axis composite cycle has been modernized with automated tool motion generation, eliminating the need for creating external drive surfaces.

New machining patterns deliver smoother transitions and better pass distribution, making it easier to program complex parts while improving efficiency in both production machining and mold & die applications.

U-Axis Turning (Preview)

Expanding capabilities in heavy machining.

A preview of U-axis turning introduces a new approach to machining—enabling turning on milling machines by rotating the tool while keeping the part stationary.

With a programmable linear axis controlling diameter changes, this capability opens new opportunities for machining along multiple axes. Available for pilot users ahead of its full release in 2026.2.

New Cloud Apps Connector

Seamless access to your connected ecosystem.

The redesigned Cloud Connector provides a modern interface for accessing cloud applications, documentation, community forums, and extensions.

With improved navigation, direct access to support, and integrated account management, users can easily stay connected, informed, and up to date within the broader ecosystem.

KnowledgeBase Manager (KBM) Enhancements

More control, better consistency in machining parameters.

A new KBM setting allows users to define whether feed rates in drilling cycles are interpreted as units per revolution or units per tooth.

This ensures compatibility across different knowledge base configurations and resolves inconsistencies when using non-standard tools, resulting in more accurate and reliable machining processes.

ESPRIT EDGE 2026.1 empowers manufacturers to automate programming, reduce risk, and adapt to increasingly complex machining demands, setting the stage for continued innovation throughout 2026.

ESPRIT EDGE 2025.4 delivers focused enhancements across turning, Swiss machining, 3-axis strategies, and simulation performance. This release is designed to increase programmer confidence helping manufacturers move from programming to production with greater certainty.

Smarter and More Reliable Turning

Turning roughing canned cycles have been refined to eliminate discrepancies between programmed toolpaths and actual machine behaviour. These improvements allow programmers to use canned cycles with greater confidence while still preserving flexibility at the machine. The result is more predictable roughing operations, reduced inconsistencies, and a lower risk of tool or part damage on the shop floor.

Advanced 3-Axis Turn Roughing with Tool Axis Variation

ESPRIT EDGE 2025.4 introduces Tool Axis Variation for 3-axis turn roughing, delivering a new level of flexibility and efficiency. This advanced strategy works seamlessly with Profit Turning and Y-axis turning tools such as Sandvik CoroPlex YT and Ceratizit FreeTurn. By enabling smarter tool engagement and improved material removal, manufacturers can achieve faster roughing cycles without compromising stability or control.

Enhanced Control for Swiss Machining

Swiss machining workflows benefit from greater control and collision prevention in this release. Tool change positions can now be defined while cancelling the tool offset, allowing more precise turret retraction and positioning. In addition, balanced roughing cycles have been optimised specifically for Swiss machines to help prevent tool collisions with the guide bushing, increasing confidence during complex roughing operations.

Higher-Quality 5-Axis Composite Toolpaths

Composite machining sees significant quality improvements in ESPRIT EDGE 2025.4. A new step-over computation for the Contour Offset pattern, along with added spiraling and rounding capabilities for both Contour Offset and Drive Profiles, results in cleaner, more consistent toolpaths. These enhancements deliver better equidistant passes, smoother motion, and improved surface quality on complex 5-axis parts.

Faster Stock Automation and Simulation Performance

Powered by SimNC, stock automation and simulation performance has been improved by up to 15 percent, particularly when working with fine tolerances in 4- and 5-axis milling. Faster material removal calculations and verification reduce waiting time between iterations, helping programmers validate toolpaths more quickly and move into production sooner.

With improved turning reliability, safer Swiss machining, higher-quality multi-axis toolpaths, and faster simulation performance, ESPRIT EDGE 2025.4 helps manufacturers program with confidence and machine with precision. Upgrade today to take advantage of these latest enhancements and keep your machining workflows efficient, predictable, and production-ready.