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CAM: Hexagon’s AI-powered Automation Slashes Machine Tool Programming Time by 75%

"Although many machines are automated, programming them is still time-consuming and laborious." AI development is taking an increasingly firm grip on all companies and organizations that develop IT support for product development and realization. The CAM area is no exception. In one of yesterday's articles, PLM&ERP News reported on Hexagon's Manufacturing Intelligence division's new AI assistant, HxGN Alix. But there is more of interest happening within the framework of the company's AI bet.
Last week, Chuck Mathews, GM of Manufacturing Software at Hexagon, revealed that it is releasing an automated programming tool for the CAM side, called ProPlanAI. This is said to reduce the time it takes to program machine tools by a remarkable 75 percent. The solution is operated within the framework of Hexagon's Microsoft Azure services built into the company's cloud-based Nexus connectivity and collaboration platform for discrete manufacturers.
ProPlanAI was presented at the Microsoft Ignite conference in Chicago recently. The two industrial IT players have a strategic partnership to redefine manufacturing with cloud technology, announced in April 2024. Hexagon's AI application applies Microsoft's Azure OpenAI Service, Azure Cosmos DB and Azure Databricks to help manufacturing companies apply their institutional knowledge, ensuring machines can be quickly and efficiently programmed to their quality standards whilst freeing up expert staff. This by applying AI to automate time-consuming process planning.
What makes ProPlanAI particularly interesting is how it can leverage human capital to achieve increased machine utilization. In addition to streamlining part programming, the technology can potentially help companies identify latent standard practice methodology, provide notification of deviations from company programming standards, and better utilize product manufacturing information (PMI) embedded in design files to achieve even more automated CNC programing.
Chuck Mathews claims that the new AI technology is the next step in the evolution of CAM programming:
"In a highly competitive market, productivity on the factory floor is critical. Although many machines are now automated, programming them is often long and laborious and requires highly skilled professionals who are thinly spread. We have partnered with Microsoft to leverage their powerful AI capabilities through Nexus, so manufacturers can increase productivity by allowing their programmers to focus on complex tasks where their knowledge has the greatest impact.”
ProPlanAI will be available to customers using Hexagon's ESPRIT EDGE CAM software from the first quarter of 2025. Customers can add the use of ProPlanAI to their package via an add-on subscription.

The idea is that ProPlanAI should ”learn” from the data created by a company’s CAM programmer. This, Hexagon believes, will enable manufacturers to automatically explore existing programming information to predict ideal results tailored to a company’s preferences, production capacity and needs. The solution will be available within Hexagon’s CAM software and powered by Nexus. Chuck Mathews claims that ProPlanAI will continuously learn and adapt, to ensure that the programs are as efficient and productive as possible.
“Because manufacturers use their own pool of data to build programs, proposals automatically reflect the knowledge and experience of individual companies, as well as the parts they produce and the machine tools they use. This ensures that new employees can quickly get up to speed, while also ensuring that there is no knowledge spillover when a person leaves a company or retires – something that is crucial in an industry facing skills shortages,” he says.

Companies can train Hexagon’s new ProPlanAI with their institutional knowledge, ensuring machines can be quickly and efficiently programmed to their quality standards while freeing up expert staff. Manufacturers can significantly increase productivity by using this solution and automate the programming of machine tools and provide users with faster access to knowledge base resources.

AI powered chat support
Furthermore, ProPlanAI will also feature a co-pilot that can guide people through the process of setting up a machine and present them with programs that work. In addition to offering support and guidance – for example, tips on how to use the software, processes for making a specific del and the best processing strategy to use – users can use chat functionality to ask specific questions and launch commands.

ProPlanAI has already been beta-tested by several industry experts, including RODIN Machining, which is moving towards fully unmanned production for milling, turning, gripper and material handling, loading and unloading machines, and tool change.

Paul Mooij, Director of Digital, at the company RODIN machining commented on the matter as follows:

“We set out to build the first autonomous factory in 2022 and we make extensive use of automation, but machine tool programming is complicated and requires experience. What makes ProPlanAI exciting is that we can leverage our human capital to achieve greater machine utilization – our team can program machines in a fraction of the time by applying their valuable skills in monitoring ProPlanAI proposals and finalizing program specifications.”

In addition to streamlining part programming, the technology can potentially help companies identify latent standard practices, provide notification of deviations from company programming practicies, and better utilize product manufacturing information (PMI) embedded in design files for even more automated CNC programming.

Strategic partnership with Microsoft
Furthermore, it can be noted that the announcement of ProPLanAI builds on Hexagon’s strategic partnership with Microsoft to redefine manufacturing with cloud technology, which was announced in April 2024.

”Microsoft’s collaboration with Hexagon is driven by a shared belief that we can transform manufacturing productivity. It’s rewarding for us to see how the AI ​​capabilities provided by Azure bring productivity-enhancing automation to expert CNC programmers, while helping new users develop faster. This is exactly the kind of transformation AI can bring to the industry, and we’re excited to see Hexagon use its manufacturing expertise to transform workplace productivity throughout the value chain with its Nexus platform,” summed up Clare Barclay, President, Enterprise and Industry, at Microsoft EMEA.

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