ModuleWorks announces the 2025.08 release of its software components for digital manufacturing and digital factory. With a focus on utilizing integrated information, this latest release of the ModuleWorks SDK comes with automated features designed to enhance process safety, toolpath generation efficiency and part quality.
SmartRoughing
Setting the right parameters for roughing often relies on programmer experience to balance material removal, tool wear and machine stability, which can result in conservative choices, longer cycle times and inconsistent results.
With SmartRoughing, ModuleWorks introduces a physics-driven toolpath algorithm that removes the guesswork. By using information on the machine’s capabilities, tool geometry and material properties, SmartRoughing automatically generates toolpaths with constant engagement and optimized chip load. This enables programmers and machine shops to achieve faster machining, longer tool life and more consistent quality while making roughing processes accessible to less experienced users.
FeedControl
Ensuring consistent chip formation is one of machining’s toughest challenges, with heat, tool load, spindle deflection and material hardening making the process unpredictable and difficult to control.
ModuleWorks 2025.08 introduces FeedControl, an intelligent feed rate optimization technology that balances chip thickness, cutting forces and spindle loads in real time. By adapting to machine-tool capabilities, tool geometry and material behaviour, FeedControl is designed to ensure process stability, protect tools and deliver consistent results.
High Dynamic Turning
In conventional turning, machining contours requires multiple tools, leading to higher tooling costs and longer cycle times due to frequent tool changes. In addition, traditional turning does not accommodate toolpaths in the Y‑Z plane, restricting process flexibility and efficiency.
The new ModuleWorks 2025.08 turning feature in combination with the FreeTurn tool removes these limitations. A single tool can now machine all contours of a workpiece in one operation, while toolpaths are created directly in the Y‑Z plane. This significantly reduces cycle times through fewer air cuts and tool changes and enables faster feed rates for more efficient machining.
Deburring - Exclude Holes and Vertical Edges
In conventional workflows, deburring holes often requires multiple passes with a spot drill with no option to exclude smaller holes. At the same time, in 3‑axis setups vertical edges cannot be filtered out, leading to additional rework.
To solve this, ModuleWorks 2025.08 introduces a new deburring enhancement that allows users to filter out holes by diameter and exclude vertical edges directly within the toolpath calculation. This gives programmers greater control, reduces redundant work and ensures deburring strategies match the exact requirements of the cutting process.
Cutting Simulation - Pixel-Perfect GPU Renderer
Standard rendering modes often fall short in delivering the visual fidelity required for high-precision machining and fine-detail inspection. Inaccurate or blurry representations of the stock state can make reliable part inspection and deviation analysis difficult.
ModuleWorks 2025.08 addresses this issue with a new GPU-accelerated rendering feature that generates pixel-perfect visuals whenever the camera is idle. It gives machinists and inspectors a highly detailed and accurate view of the current stock, making it easier to spot deviations and verify machining results with confidence. The sharp inspection visuals lead to trustworthy analyses, enhancing quality control and supporting high-precision requirements in modern manufacturing environments.
