Hybrid Milling, Additive Manufacturing

DMG MORI offers a hybrid additive manufacturing machine, the Lasertec 65 3D. The machine uses a blown-powder deposition welding process in combination with a laser to melt powder onto a base material. The machine builds up the component layer-by-layer, but only uses the powder where it is needed. In contrast to a powder-bed process, this technique is said to reduce the necessary quantity of powder and build up material more quickly, the company says. The hybrid machine enables a combination of additive and subtractive manufacturing in a single setup, and is suited for hybrid production of components, including repair work and the application of partial or full coatings.

The basic machine is a DMU 65 MonoBlock five-axis machining center for high-precision milling operations including five-axis simultaneous machining. The integrated laser head is equipped with a 2.5-kW diode laser. The head is automatically exchangeable and moves out of the working area of the machine during milling operations.

The company has also expanded its additive manufacturing program with the Lasertec 4300 3D. This second hybrid machine adds the possibility of turning operations to laser deposition welding and five-axis milling, so that rotation-symmetric components can be produced with the hybrid process. The machine is equipped with a mirrored C axis. Workpieces can be machined on the rear side with the counter-spindle, enabling six-sided complete machining of the finished part.