SINUMERIK 828D provides digital twin programming functionality for compact and mid-range machine tools
• SINUMERIK Run MyVirtual Machine is now available for the SINUMERIK 828D machine, providing digital twin programming for the compact and mid-range machine market in the United States for the first time
Siemens — a global leader in industrial machining — has introduced digital twin programming for the SINUMERIK 828D CNC, extending a capability long associated with high-end machining centers to the compact and mid-range machine market. The company will demonstrate the new hardware and software at IMTS 2026 in Chicago.
SINUMERIK 828D is the control unit that translates a part program into coordinated motion of a machine’s axes and spindle. It runs turning, milling, and grinding machines in the compact and mid-range segment, where a machinist typically writes or imports a program, then proves it out by stepping through it cautiously on the machine itself. However, this practice occupies the spindle and carries a risk of crash.
Proving out the program before the machine runs
A digital twin addresses this and related risks by modelling a machine and capturing its kinematics, control behavior, working area, clamping, and tooling. The new PPU271.5, PPU270.5, PPU290.5, and PU272.5 828D processor units provide upgrade access to software version 5.25 with SINUMERIK Run MyVirtual Machine. Using this software tool, machinists can create, validate, and optimize programs against the model while production continues, with detailed visualization of material removal at every phase of the program.
Because the simulation exposes potential collisions in advance, it decreases production risk and cuts setup time on the machine by up to 20%. It also provides a learning space for new operators without consuming spindle hours or damaging tooling. Another advantage is providing a test bed to evaluate improvements before implementation.
SINUMERIK ONE, the digital native CNC from Siemens, has offered this capability on higher-end machining centers for years, so it is a proven-in-use technology, and these capabilities are now available for compact machines as well.
A re-designed operating concept
The re-designed SINUMERIK 828D CNC accompanies the new processor units, pairing significantly larger 12.1-inch and 15.6-inch screens with mechanical keys, providing operators with tactile control of the functions they reach for most frequently. Additionally, Create MyHMI/3GL empowers machine builders and integrators to tailor the interface to specific applications.
Connectivity, energy transparency, and security
The X120 interface on the new processor units connects to external devices, such as the SINUMERIK HT 10 handheld terminal and edge devices, widening the range of applications covered by a single controller. For example, operators can call up an analysis function to scrutinize energy consumption right at the machine. The new processor units also add a security archive, user management capabilities, and certificate storage, preserving data integrity as more machines join plant networks.
“Digital twin programming has long been a high-end capability, but it stands to benefit shops running compact and mid-range machines the most because they can least afford tying up a spindle to prove out a program. Adding Run MyVirtual Machine to the 828D system empowers machinists to first work through a job virtually, so the program is right by the time they load it to the machine,” says Chris Pollack, Machine Tool Technology Application Center Manager, at Siemens.
These capabilities are available now. To learn more about the latest generation of SINUMERIK 828D, contact your Siemens representative, or visit usa.siemens.com/828D.
Siemens Digital Industries (DI) empowers companies of all sizes within the process and discrete manufacturing industries to accelerate their digital and sustainability transformation across the entire value chain. Siemens’ cutting-edge automation and software portfolio revolutionizes the design, realization, and optimization of products and production. And with Siemens Xcelerator – the open digital business platform – this process is made even easier, faster and scalable. Together with our partners and ecosystem, Siemens Digital Industries enables customers to become a sustainable Digital Enterprise. Siemens Digital Industries has a workforce of around 70,000 people worldwide.
