What’s New in MecSoft CAM 2026
This article discusses some of the major enhancements found in the MecSoft CAM 2026 release for RhinoCAM and VisualCAD/CAM, highlighting significant advancements in automation and performance. Key features include an automatic 5 Axis auto-roughing module, innovative 4-axis extrusion machining, and a new 2½ Axis auto-deburring operation. A major highlight is the GPU-accelerated tridexel simulation, which offers performance improvements of up to 10x using NVIDIA graphics. The update also introduces expanded Python-based post-processor enhancements and stability improvements driven by AI tools. Please read the additional details below.
5 Axis Auto-Rough
The 5-Axis 3+2 Auto-Roughing method, introduced in the 2026 release of MecSoft CAM, is an automated indexing module designed to simplify the roughing of complex multi-sided parts using a 5-axis machine. Refer to the key details of this automated toolpath method below.
Core Functionality
- Automated Setup Generation: The system automatically analyzes the 3D part model and the stock model to determine the most efficient orientations for machining.
- 3+2 Indexing: It uses “3+2” (indexed 5-axis) machining, where the tool is oriented at specific fixed angles to machine the part from different sides rather than moving all five axes simultaneously during the cut.
- Intelligent Approach: The software identifies the best directions to approach the part to remove the maximum amount of material while avoiding collisions, then automatically creates the necessary indexed setups.
Key Features
- No Control Geometry Required: Unlike traditional methods that require the user to manually select curves or boundaries, this method performs a global analysis of the stock and part to generate toolpaths automatically.
- Adaptive Roughing: For each generated setup, the system creates Adaptive Roughing toolpaths. These are high-performance paths designed to maintain a constant tool load, which is ideal for efficient material removal.
- Flexibility: Users can choose to let the system generate the entire toolpath or simply generate the setups only, allowing the user to manually add or refine operations afterward.
Usage and Benefits
- Speed: This method is specifically intended to “turbocharge” production by significantly reducing the time spent manually setting up complex, multi-sided 5-axis jobs.
- Location in Software: The feature is found in the software menu under Program > 5-Axis > Auto-Rough.
Axis Extrusion Machining
This method generates a toolpath by “extruding” a specific profile along a defined rail curve. Refer to the key details of the 4 Axis Extrusion toolpath method below.
- No 3D Model Required: A major highlight of this feature is that you do not need a full 3D part model. The toolpath is generated simply by selecting a profile curve and a rail curve.
- True 4-Axis Motion: Unlike “wrapped” toolpaths, this is a continuous 4-axis operation that moves all three linear axes (X, Y, Z) and the rotary axis simultaneously.
- Dipping Below the Rotary Axis: In standard 4-axis operations, the tool typically cannot move below the center of the rotary axis. This method removes that limitation, allowing the tool to reach recessed areas and ensure no stock is left behind.
- Performance: This method is very fast compared to older “drive surface” methods because it doesn’t need to calculate complex surface normals from a 3D model.
4-Axis Extrusion Projection
This variation functions similarly to the standard extrusion method but incorporates an underlying 3D part model for more complex shapes. Refer to the key details of the 4 Axis Extrusion Projection toolpath method below.
- Projecting onto Surfaces: Instead of the toolpath being fixed strictly to the extrusion curves, it is projected down onto a 3D part model, which can be a surface or a mesh.
- Geometric Flexibility: This allows for machining parts that are entirely above or below the rotary axis, or parts that have varying surface depths that a simple extrusion cannot account for.
Location in the Software
Both operations are located in the 4-Axis menu of the software under Program > 4 Axis > Extrusion & Projection Extrusion
GPU-Accelerated "Tridexel" Simulation
Version 2026 introduces a major performance enhancement in MecSoft CAM: the GPU-accelerated Tri-Dexel Simulation. This new module leverages modern graphics hardware to significantly decrease the time required to visualize material removal. Refer to the key details of the GPU-Accelerated “Tridexel” Simulation enhancement below.
Core Technology: Tri-Dexel vs. Previous Methods
The three Cut Material Simulation methods now available in version 2026 are compared below with the new TripDexel method benefits mentioned:
- Voxel (Box) Method: Fast but low resolution and limited to 3-axis machining. It cannot simulate undercuts or multi-sided setups.
- Polygonal Method: Highly accurate for all 2-5-axis motions but computationally expensive and slows down as toolpath complexity increases.
- Tri-Dexel (New): A “dexel” is a voxel with depth calculated in all three axes (X, Y, and Z). It combines the speed of voxel-based calculations with the accuracy and direction-independence of the polygonal method.
Key Features and Performance
- GPU Acceleration: The simulation uses the Nvidia GPU (Graphics Processing Unit) and its dedicated RAM to perform computations rather than the main CPU.
- Speed Improvements: The method is typically 5 to 10 times faster than the polygonal method. Crucially, performance increases as the toolpath becomes more complex; while polygonal methods slow down with more “polygons,” the Tri-Dexel method handles complexity much more efficiently.
- Visual Fidelity: Despite the speed, the quality is nearly identical to the polygonal simulation, allowing users to see fine details without the long wait times.
Real-World Time Comparisons
Here are several example “time trials” to demonstrate the performance leap:
- 2½ Axis (78 XY Instance Array): Reduced from 33 minutes to 162 minutes (over 2x faster) for a job with 920,000 cut motions
- 3-Axis (Two-Sided Wheel Hub): Reduced from 12 minutes to 2 minutes (over 5x faster) for a job with 400,000 cut motions.
- 4-Axis (Filigree Table Leg): Reduced from over 1 minute to 10 seconds (7x faster) for a job with 67,000 cut motions.
- Indexed 5-Axis (Complex Block): Reduced from 2 minutes to 18 seconds (6.5x faster) across 13 separate setups and 250,000 cut motions.
Requirements
To utilize this feature, the computer must have an Nvidia graphics card. Higher-end Nvidia cards with more graphics memory will result in even faster, “near-instant” simulations.
2½ Axis Automatic Deburring
A 2½ Axis Automatic Deburring operation is introduced as a new feature in the 2026 release of MecSoft CAM. It is designed to automatically detect and break sharp edges on a part to create a safer and more finished product. Refer to the key details of the 2½ Axis Automatic Deburring toolpath method below.
Key Features & Capabilities
- Automatic Edge Detection: The system analyzes the 3D part model to identify all available sharp edges. This removes the need for the user to manually select geometry for deburring.
- Tool Versatility: A major advantage of this method is that it supports standard ball mills. Users are not required to have a specialized chamfer tool or V-mill to break edges, although chamfer mills and taper tools are also supported.
- Selective Deburring: While the tool can automatically find all edges, users still have the option to “selectively debur” specific edges if they only want to process certain areas of the part.
Safety and Automation
- Full Gouge Checking: The operation is fully automated and gouge-checked against the part geometry and fixtures. If a chosen tool is too large to reach an edge without hitting an adjacent wall or feature, the software will automatically skip that edge to prevent damage.
- Fixture and Avoidance Awareness: The toolpath honors defined avoidance geometry and fixtures, ensuring the tool does not collide with clamps or work-holding devices.
Customization Parameters
- Sharpness Angle Threshold: Users can adjust the “sharpness angle threshold” to determine which edges the software identifies as “sharp.” For example, edges at 135 degrees can be ignored or included based on this setting.
- Edge Specifications: Similar to standard chamfering, users can define the size of the deburr by specifying the width or height (e.g., a 0.005” break).
- Tool Tip Clearance: There is an option to set a tool tip clearance, which allows the tip of the ball mill to drop slightly below the edge for a cleaner cut.
Arc Feedrate Optimization
There is a new Arc Feedrate Optimization enhancement in the 2026 release. This feature is an expansion of existing “Slow Down in Corners” logic, specifically designed to handle arc motions more intelligently. Refer to the key details of the Arc Feedrate Optimization enhancement below.
Core Functionality: Deceleration and Acceleration
The primary goal of this feature is to manage machine momentum when transitioning into and out of circular motions:
- Pre-Arc Deceleration: Users can now specify a “distance to reduce before” an arc starts. This tells the machine to begin slowing down to a defined percentage of the cut feed rate before the tool actually hits the curve.
- Post-Arc Acceleration: Similarly, a “distance after” can be set, allowing the tool to complete the arc and move a short distance into the next linear segment before accelerating back to 100% feed rate.
Smart Triggering Logic
To prevent the machine from constantly “stuttering” during high-speed machining or on smooth, tangent paths, the system uses specific filters:
- Corner Angle Limits: The optimization is not triggered by every arc. It only kicks in when the tool is “rounding a corner”—specifically when the corner angle exceeds a user-defined limiting threshold.
- High-Speed Machining Protection: If you are using tangent arcs for high-speed paths, the software recognizes these as smooth transitions and will not apply the slowdown, maintaining a consistent flow.
Practical Example
The demonstration above shows a profiling operation where:
- The base feed rate is set to 100 units for easy visualization.
- As the tool approaches a G02 or G03 arc motion, the feed rate is automatically reduced to 25%.
- Once the arc is completed and the tool clears the specified “after” distance, the feed rate jumps back to 100%.
Settings Location
This feature is found under the Toolpath Optimization tab, which has been added to many standard toolpath operation types in the 2026 version.
Drill Point Sorting
New in MecSoft CAM 2026, is a Drill Point Sorting enhancement. This is a significant productivity feature for machining parts with numerous holes, such as mold plates with ejector pins.
Here is a detailed summary of the features:
Sorting Between Operations
The primary enhancement is the ability to sort drill points between separate operations, rather than just within a single operation.
- The Problem: Previously, sorting (like minimum distance or directional) only applied to the holes defined within one specific operation.
- The Solution: A new checkbox, “Start closest to the last point of the previous operation,” allows a subsequent operation to analyze where the previous tool finished its last cut.
- How it Works: The system identifies the final drill point of the preceding operation and selects the hole in the current operation that is physically closest to it to begin the next sequence.
Reduced Non-Cut Time
By linking the end of one operation to the start of the next, the software significantly reduces:
- Retracts: Fewer unnecessary vertical movements between hole sets.
- Transfers: Shorter rapid travel distances across the part.
Hybrid Sorting Logic
The feature works in tandem with existing sorting methods. Once the “closest start point” is established to bridge two operations, the internal sorting logic of the current operation (e.g., top-to-bottom or minimum distance) takes over to complete the remaining holes in that set.
Additional Enhancements
Here are just some of the miscellaneous but powerful enhancements coming to the 2026 release of MecSoft CAM. These features focus on specialized machining logic, visualization improvements, and performance stability. Refer to the key details of the additional 2026 enhancements below.
Three-Axis and Five-Axis Machining Updates
- Flats-Only Output: A new checkbox for three-axis operations allows the software to automatically analyze the part and only generate toolpaths on detected flat areas. This is particularly useful for terrain models or parts where only horizontal surfaces require specific finishing.
- Fixed Tool Axis for 5-Axis: Users can now lock the tool axis in a specific orientation for five-axis operations rather than relying solely on surface normals. This provides more control over how the machine approaches complex geometry.
- Angle Limit Overlaps: The software now handles machines that can rotate slightly beyond their standard 0–360 degree limits (e.g., -10 to 370 degrees). Previously, hitting a “seam” would trigger an unnecessary retract; the new logic allows for continuous machining through these overlapping zones.
Drilling and Visualization Enhancements
- Start/End Point Display: To aid in visual verification, drilling operations now feature explicit markers. Red markers indicate the first cut point (start), and Green markers indicate the final cut point (end), making it easier to verify sorting patterns in complex hole sets.
- Drill Point Sorting: As mentioned above, the sorting logic now bridges the gap between separate operations to minimize “air time” by starting a new operation at the hole closest to the previous operation’s end point.
Stability and AI-Driven Performance
- AI Code Optimization: MecSoft has begun using AI tools to audit and optimize their underlying source code. This has resulted in stability improvements and significant performance gains.
- Speed Increases: Some areas of the software, specifically 2½ Axis sorting operations, have seen performance increases of up to 10x compared to previous versions.
Fixture Support
- Individual Setup Fixtures: As mentioned above, fixtures can now be assigned to specific setups rather than the entire job, and users can define a precise “clearance distance” to ensure the tool stays away from clamps or bolts.
Post-Processor Enhancement Features
Post-Processor Enhancements focus on the transition to and expansion of Python-based post-processing, which allows for significantly more flexibility and control than legacy post systems.
The key features include:
- Expanded Python Post-Processor Support: Building on the introduction of Python posts in previous versions, the 2026 release adds more “event handling” capabilities. This allows the software to generate advanced post-processors for complex machinery that standard G-code generators struggle with.
- Support for Dual-Head/Multi-Spindle Machines: The new system can now handle machines with dual heads that cut the same pattern simultaneously using two different spindles.
- Non-G-Code Proprietary Formats: The Python post-processor now supports machines that do not use standard G-code, such as specialized woodworking machines from brands like Holzer, Woodflash, and Biesse. These machines often use proprietary languages that the new post engine can handle.
- Rotated Plane Machining Improvements: There is now significantly more control over switching between rotated planes. Specifically, the system can better manage whether or not to introduce a tool change when moving between different indexed planes.
- Complex Event Handling: The Python post can now detect specific tool numbers to trigger specialized functions, such as activating or deactivating a “drill bank” based on encoded tool values.
These enhancements essentially allow MecSoft to develop post-processors for almost any machine, regardless of how non-standard its language or mechanical configuration may be.
API Enhancements for Power-Users
The API Enhancements in version 2026 refer to the RhinoCAM API improvements. These enhancements are designed for power-users, integrators and large companies that need to automate complex workflows or create custom front-end interfaces to RhinoCAM.
Below is a detailed summary of the RhinoCAM API improvements in version 2026::
Core API Enhancements
- Expanded Support for Setups and Operations: The API now includes broader support for managing machining setups and various operation notations.
- New Operation Types: Specific API support has been added for several machining methods based on user requests, including:
- Spiral Machining
- Hole Pocketing
- Hole Profiling
- Tapping
- Workflow Automation:
- Knowledge Base Integration: Users can now programmatically import and export to Knowledge Bases via the API, a feature previously unavailable.
- Copy Workflows: The API now supports “copy workflows,” allowing for easier replication of machining logic.
- Simulation & Saving: Power-users can now trigger simulations and save machining operations directly through API calls.
Use Cases for Power-Users
- Custom Interfaces: The RhinoCAM API is now robust enough that a developer could write a completely custom front-end for the standard RhinoCAM configuration if the default interface does not meet their specific needs.
- Shop Floor Simplification: Large organizations can use these tools to simplify the CAM process for shop floor users or customers by automating repetitive tasks and stripping away unnecessary complexity.
