OPEN MIND Application Example: CNC Bike
A Successful hyperMILL® Project in the World of Sports
03.11.2026 — A downhill race bike CNC-milled entirely from high-strength aluminum won the 2025 IXS Downhill Cup, among other races, and is currently back in competition. The creator of this special bike is Bernd Iwanow, Managing Director of CNC Future Technics GmbH. The hyperMILL® CAD/CAM suite from OPEN MIND Technologies AG implemented 5-axis machining and simulation-supported manufacturing during development to significantly benefit the “Fracebike”.
Bernd Iwanow had a vision to develop his own high-end bike and even founded a second company for this purpose under the name CNC Bike GmbH. He spent over a year working on design and development before the first prototype was manufactured. hyperMILL® not only enabled precise 5-axis machining of complex components but also fully harnessed the potential of the Hermle machining centers at CNC Future Technics. To achieve perfect surface quality, hyperMILL® offers special strategies for high-precision machining, a must for the visual aesthetics of a high-end bike. Thanks to functions such as “Surface Precision Mode,” in which toolpaths are calculated directly on the surfaces of the CAD model, a particularly uniform milling finish is achieved.
For example, a bike CNC-milled and designed in hyperMILL® won the 2025 IXS Downhill Cup series.
Milling Strategies and Simulation
Another milling strategy that Iwanow particularly values is “Smooth Overlap,” which ensures flawless transitions between individual machining areas. “Flawless machining is crucial, especially for prototypes: Every step has to be right, and the first part has to fit,” says Iwanow. With hyperMILL® VIRTUAL Machining, he has a reliable, NC-code-based simulation at his disposal for this purpose.
“We’re delighted by the success of the Fracebike and the growing interest in Iwanow’s work within the community. At the same time, it was great to see how skillfully he leveraged the technical capabilities of hyperMILL®. I wish him and the riders of his bikes continued success, and, of course, injury-free rides,” says Dr. Josef Koch, CTO of OPEN MIND Technologies, himself a passionate mountain biker and owner of a one-of-a-kind bicycle by Bernd Iwanow.
hyperMILL® VIRTUAL Machining Center: Material Removal Simulation for Milling Operations
Key Facts at a Glance
- Sports Success: A CNC-milled downhill race bike wins the 2025 IXS Downhill Cup, among other races.
- An extraordinary project: A race bike made entirely of high-strength aluminum, developed by Bernd Iwanow, CEO of CNC Future Technics GmbH.
- Precise 5-axis machining: hyperMILL® enables the production of complex geometries with high surface quality.
- Reliable manufacturing: NC code-based simulation with hyperMILL® VIRTUAL Machining helps ensure error-free machining right from the first part.
The main frame of the Fracebike is made of high-strength aluminum.