Additive manufacturing of finished part quality

In addition to the special exhibition Metal meets Medical shows DMG Mori on the adjacent exhibition space of the Rapid Area with the "lasertec 65 Additive Manufacturing" an unprecedented hybrid machine. This integrates the generative laser cladding in a full 5-axis milling machine.

In times of ever shorter product life cycles and increasingly complex and individualized components generative process can help companies to manufacture new products faster. For generative manufacturing processes enable the production of complex geometries and workpieces. The unique combination of technologies according to the supplier of laser cladding by powder nozzle and milling allows users completely new application and geometry options. In the method, a job process is implemented through Metallpulverdüse which is up to 20 times faster than the generation in the powder bed.

Alternating deposition welding and milling

For the generative manufacturing the "lasertec 65 Additive Manufacturing" is equipped with a 2 kW diode laser for laser cladding. The selected integration full 5-axis milling machine Deckel Maho in stable mono-block design allows users but also high-precision milling operations. "The hybrid machine is due to the fully automatic change between milling and laser operation for the complete machining of complex parts with undercut, but also for repair work and the application of partial or complete coatings for medical, mold design and engineering," says Friedemann Lell, sales manager Sauer lasertec, pfronten.

The laser is off the bench along with powder coating head in the HSK tool holder of the milling spindle. It can be automatically parked in a secure docking station, as long as the milling operations are performed on the machine. The control for the laser process is housed in a separate cabinet, which facilitates the integration of this system into other machines from DMG Mori.

Machine large components generative

Components can be constructed in several stages. It can be milled between the cladding to edit points on the final accuracy that can not be achieved in the finished component due to the component geometry from the router. Conclusion: The hybrid machine combines the advantages of milling, such as high precision and surface quality with the flexibility and the high build-up rate of powder deposition welding. "With integral components, where today by milling to 95 percent of material is removed, is built with only additive process where material where it is needed. This leads to significant raw material and cost savings, "says Lell. The combination of cutting and additive methods should quickly gaining in importance as it gives users a lot of new possibilities and advantages.

Highlights of the "lasertec 65 Additive Manufacturing"

·         Unique combination of laser application and milling enables the highest surface quality and precision component

·         Laser cladding with powder nozzle is 20 times faster than the powder bed process

·         Feasibility of complete components

·         3D geometries can be realized even with undercuts

·         Repair work in tool and Fomenbau

·         Applying wear layers

·         Complete machining with fully automatic switching between milling and laser operation

·         Large work area for workpieces up to 650 mm diameter, 360 mm height and max. 1000 kg weight

·         Accessibility and ergonomics: 1,430 mm door opening (from the front)

·         Only 7.5 m ² floor space