DMG Mori Add, remove material in single setup with milling, metal deposition unit

Editor: Eric Culp

A version of the hybrid machine is to be displayed at Euromold 2013.

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Commercially available machines are expected to be ready by September 2014, according to the supplier.
Commercially available machines are expected to be ready by September 2014, according to the supplier.
(Source: DMG Mori)

DMG Mori said it will introduce a machine concept that offers both 5-axis milling and metal deposition processes.

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The company’s Sauer Lasertec unit worked with DMG Mori’s US operations to integrate laser metal deposition technology into the hybrid machine concept, which is based on a DMU 65 Monoblock machine tool.

Commercially available technology will reportedly be demonstrated at a pair of machine tool shows in September 2014: IMTS in the US and AMB in Germany. At the same time, the series start-up is planned, the company said.

DMG Mori said the concept study at Euromold will feature a Lasertec 65 Additive Manufacturing machine fitted with a 2kW diode laser for laser metal deposition. According to Gregory A. Hyatt, senior VP & CTO of DMG Mori Advanced Solutions Development, “By combining additive manufacturing with milling or turning in one machine, additive technologies are no longer limited to small workpieces. Our focus is to create a solution for more typical and larger workpieces found in industries such as aerospace, mould & die and energy, and for faster, more productive and economical justifiable deposition rates.”

The powder nozzle process allows for the manufacture of large parts, and the build rate of up to 3.5kg/h makes this process as much as 20 times faster than laser sintering in a powder bed, according to the supplier.

It explained that the combination of additive steps with milling makes completely new applications possible. For example, the part can be built in sections, with milling operations of important areas occurring before further material additions block these areas from the cutting tool.

The hybrid machine combines the advantages of milling – high accuracy and surface finish – with the flexibility and high build rate of laser powder deposition, and it can cut costs, too, according to Friedemann Lell, head of sales at Sauer Lasertec. “For integral parts that are traditionally milled with a material waste rate of ninety-five per cent and more, a significant cost saving can be achieved and the rate of waste can be reduced to about five per cent.”

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