LIMASSOL, Cyprus, Sep 23, 2025 – Industrial robotics is getting an upgrade as ENCY Software introduces ENCY Hyper, a hybrid simulation and programming system for robots and auxiliary equipment. Designed for tablets and PCs, ENCY Hyper combines offline programming with the responsiveness of real-time methods in a single workflow. The system offers features such as AI-powered auxiliary tools, built-in collision avoidance, and multi-brand robot calibration. ENCY Hyper will be presented at EMO Hannover 2025.
What is ENCY Hyper – At a Glance
- Programming & simulation – A hybrid system for industrial robots and auxiliary equipment that merges offline precision in a touch-optimized workflow.
- Key capabilities – Real-time robot and sensor feedback; AI-powered auxiliary tools; built-in collision avoidance; complete digital twin of the robotic cell; multi-brand robot calibration and programming from a single interface.
- Use it solo or with ENCY Robot – ENCY Hyper can be used for pick-and-place, palletizing, packaging, or assembly – or paired with ENCY Robot for applications like milling, welding, spraying, or grinding.
- Interactive environment – The system communicates to the robot, allowing real-time execution, testing, and adjustment of motion. Engineers can refine control logic and movement on the spot, maintaining accuracy from design through deployment.
What’s Broken Today – And Why It Slows You Down
- Online (teach-pendant) programming – Intuitive but limited. It works for small changes and runs on the controller. It cannot handle complex paths, relies on operator skill, lacks full-cell simulation, and requires testing on the real system, increasing risk and downtime.
- Offline (CAM + simulation) – Powerful, but brittle at hand-off. You can generate specific paths and test them in a digital twin. But issues (mounting offsets, gripper wear, tilted fixtures) create gaps between simulation and reality. Even on-cell change on the robot requires engineers to return to the office, update the program, transfer it to a USB stick or network share, reload it on the controller, and test again. This loop repeats for every adjustment, increasing downtime.
How ENCY Hyper Eliminates the Trade-Off
ENCY Hyper unifies a digital twin and CAM-level accuracy with robot communication in one hybrid, touch-optimized environment.
Addresses Online (Teach-Pendant) Limitations
- Scale without point-by-point teaching – Define what to pick and where to place; Hyper generates and executes motion for routine tasks like palletizing, packaging, or assembly.
- See before you move – Keep the responsiveness of online edits while gaining simulation of the complete robotic cell, so you’re not “testing blind” on production hardware.
- Safer, faster debugging – Stream commands to the controller, step through with live robot and sensor feedback, pause instantly, and resume safely.
Fixes Offline (CAM + Simulation) Hand-Off Issues
- Eliminates the office↔cell loop – Instead of exporting, copying, and walking files back and forth, Hyper streams programs to the robot for execution and adjustment.
- Closes the twin-to-reality gap – Use point-and-confirm calibration: show a few real pick/place points; Hyper updates the digital twin and automatically automatically recalculates the rest.
- Built-in collision avoidance – As you adjust on the cell, Hyper continuously checks and generates obstacle-aware paths to keep edits safe.
- Multi-brand, one interface – Calibrate and program robots from different vendors through a single UI; add drivers to expand coverage without retooling your process.
- Right-sized effort for quick jobs – Skip heavyweight CAM rebuilds when you need small changes; make them with immediate feedback.
Where ENCY Hyper Delivers – From Simple to Complex
ENCY Hyper’s hybrid workflow applies from cells to toolpaths, combining digital-twin confidence with on-cell execution. Examples below:
Simple Operations
- Brownfield palletizing with drifting fixtures (6-axis robot on a 7th axis, palletizing/depalletizing) – Stream programs to the controller, tweak layer patterns at the cell, and recalibrate offsets from real pick/place points; collision checks help maintain clearances near posts and guards.
- Kitting and light screwdriving (collaborative 6-axis cobot, assembly/screwdriving) – Nudge targets on a tablet and stream updated moves in real time; I/O feedback confirms each step without point-by-point reteaching.
Advanced Operations (with ENCY Robot)
Programs created in ENCY Robot can also run in ENCY Hyper. The key difference is location – changes are made at the robot without returning to the office. Engineers can adjust part positions, entry and exit paths, batch size, tray/box destinations, step size, and number of passes in Hyper. For new parts, the CAM project is updated in ENCY Robot. For production changes on the same part, adjustments are handled in Hyper.
- Robot milling (6-axis robot, optional linear 7th axis; spindle) – Programs are generated in ENCY Robot and tuned on the floor in Hyper (approach/exit edits, feeds, local adjustments).
- Grinding/polishing/deburring (6-axis robot; abrasive/finishing tools) – Generate toolpaths in ENCY Robot; in Hyper, adjust passes, step size, and approach/exit moves interactively next to the robot.
- Coating/painting (6-axis robot + rotary table) – Use ENCY Robot for path definition; in Hyper, refine process parameters like number of passes and start/stop timing at the cell.
- Arc welding (6-axis robot + 2-axis positioner; GMAW/TIG) – Define and simulate in ENCY Robot; at the cell, Hyper lets you adjust weld parameters such as weave step, pass length, and strategy without rebuilding the CAM project.
ENCY Hyper combines the benefits of online edits and offline programming in one system. This approach speeds commissioning, supports short production runs, and reduces downtime. The system is designed for manufacturing and robotics engineers, shop-floor operators, technicians, system integrators, and OEMs.
Source: ENCY Software
About ENCY
ENCY Software Ltd., headquartered in Limassol, Cyprus, offers a CAD/CAM/OLP software ecosystem aimed at enhancing engineering and manufacturing workflows. Their ENCY X platform provides tools such as ENCY for CAD/CAM operations, ENCY Robot for offline robot programming, ENCY Tuner for NC-code simulation, and ENCY Clouds for cloud-based workspaces. The solutions serve industries including architecture, automotive, aerospace, consumer products, education, electronics, energy, entertainment, industrial machinery, medical, shipbuilding, and woodworking.