Four Complete Process Chains for Powder Bed and Powder Nozzle Additive Manufacturing Technology

Customized manufacturing solutions: As a full-liner for the additive manufacturing of metal parts DMG MORI combines its LASERTEC 3D and LASERTEC 30 SLM 2nd Generation models with conventional CNC machines.

As a global full-liner with over 20 years of experience in the ADDITIVE MANUFACTURING of metal parts, DMG MORI stands for innovative manufacturing technologies and a worldwide service. The portfolio includes four complete process chains for additive processes using powder nozzle or powder bed technologies. For this integral offer, DMG MORI combines its LASERTEC 3D models and the LASERTEC 30 SLM 2nd Generation with the machining centers from its broadly diversified machine portfolio. Complete revision of the LASERTEC 30 SLM 2nd Generation is another proof of the machine tool manufacturer’s commitment to continuous further development in the field of additive manufacturing. With its user-friendly Stealth design, this second generation of the powder bed machine impresses through increased process autonomy as well as a high level of work safety.

The steady growth of ADDITIVE MANUFACTURING technologies is alerting designers to the potential of this method in the construction of components and tools. The quality of workpieces produced with additive methods is also increasing as is machining speed. This has resulted in consistently positive forecasts: ADDITIVE MANUFACTURING is expected to grow by 20 to 30 percent by the year 2020. “In particular as a complement to conventional production methods powder nozzle and powder bed processes offer expedient and extremely promising possibilities”, explains Patrick Diederich, responsible for ADDITIVE MANUFACTURING at DMG MORI.

With its broadly diversified machine portfolio in both machining and ADDITIVE MANUFACTURING DMG MORI’s approach to this topic is clearly holistic. Patrick Diederich goes on to tell us: “If additive manufacturing is to become established on the shop floor, it is essential to integrate this method into existing production systems and process chains – especially where successfully progressing from prototype and small series production to serial production is concerned.” Cost efficiency plays a key role in this respect. “It is imperative to awake an awareness for the possibilities offered by additive manufacturing, which start with the design of components and extend throughout the entire life cycle of the product.” This is the only way to exploit its enormous potential.

DMG MORI has performed successfully on the market for over five years now with the combination of laser deposition welding and metal-cutting machining on the machines of the LASERTEC 3D hybrid series. In addition to establishing and expanding the digital process chain DMG MORI has also developed to become a full-liner in ADDITIVE MANUFACTURING. While the LASERTEC 65 3D is geared solely towards laser deposition welding as a complement to existing machining centres on the shop floor, the LASERTEC 30 SLM 2nd Generation in the new Stealth design expands the portfolio to include the powder bed method using selective laser melting. Thanks to the combination of additive manufacturing technologies with conventional CNC machines DMG MORI has realised four individual needs-based process chains.

The portfolio includes four complete process chains for additive processes using powder nozzle or powder bed technologies.

 LASERTEC 3D hybrid

Additive manufacturing using a powder nozzle and conventional machining in a single set-up

The LASERTEC 3D hybrid and LASERTEC 3D machines are available for users in the field of laser deposition welding with a powder nozzle. The first combine additive manufacturing and conventional machining in a single set-up. The LASERTEC 65 3D hybrid is designed for the 5-axis simultaneous machining of parts measuring up to ø 19.7 x 15.7 inches. The LASERTEC 4300 3D hybrid enables 6-sided turn & mill operations for workpieces with sizes up to ø 26 x 59 inches. Designed for the complete machining of demanding geometries, the LASERTEC 3D hybrid machines enable flexible changeover between laser deposition welding using a powder nozzle and mill or turn operations.

 LASERTEC 65 3D

Four complete process chains for powder bed and powder nozzle technology

A second process chain based on the powder nozzle includes the compact LASERTEC 65 3D for 5-axis laser deposition welding and a machining centre for final finishing of the additively manufactured components. This makes the LASERTEC 65 3D the ideal addition to the machines already installed on the shop floor, a combination that ensures optimum utilisation of production capacity. With travel paths of 735 × 650 × 560 mm the work area of the LASERTEC 65 3D is around 40 percent larger than the hybrid version and its footprint is about 45 percent smaller.

DMG MORI completes the process chains in laser deposition welding with NC programming in hybrid CAD/CAM with SIEMENS NX, technology parameters from a material database plus process monitoring and documentation. “Different materials can also be combined in one building process in the two process chains with the powder nozzle, a capability that can give parts special properties”, adds Patrick Diederich.

 LASERTEC 30 SLM 2^nd Generation

Two process chains with ADDITIVE MANUFACTURING in the powder bed

Cannot be achieved conventionally: Function integration and lightweight structures ensure shorter cycle times.

DMG MORI offers the LASERTEC 30 SLM 2^nd Generation for ADDITIVE MANUFACTURING in the powder bed (Selective Laser Melting). The second generation of the machine has a 300 × 300 × 300 mm construction volume and with its Stealth Design offers optimum user comfort. Two process chains can be realised with powder bed technology: On the one hand, workpieces produced by means of additive manufacturing can be finished to the required surface quality on a milling machine such as the 5-axis DMU 50 3rd Generation. On the other hand, the LASERTEC 30 SLM 2^nd Generation can finish previously milled base plates and bases without any need for support structures.

 LASERTEC 30 SLM 2^nd Generation

Fast material exchange with the rePLUG powder module system

As an integral software solution for CAM programming and machine control CELOS rounds off the LASERTEC 30 SLM 2^nd Generation process chains. The coordinated and uniform user interface enables parts to be programmed externally with minimum time expenditure and transferred to the machine – regardless of their complexity. Thanks to the efficient flow of information and intuitive operation CELOS ensures optimum processes in the pre- and post-processing of additively manufactured parts. In addition the open system of the LASERTEC 30 SLM 2^nd Generation enables individual adjustment of all machine settings and process parameters, right through to include an unlimited choice of material suppliers.

 LASERTEC 30 SLM 2^nd Generation

Fast material exchange with the rePLUG powder module system

Flexibility, productivity and process reliability are the outstanding features of the LASERTEC 30 SLM 2^nd Generation that make it an impressive machine on the market of additive systems for selective laser melting. One highlight is the flexible powder module rePLUG. “This enables a material exchange in less than two hours. In addition, the closed material circuit ensures a high level of work safety and process autonomy,” explains Mathias Wolpiansky, Managing Director of REALIZER GmbH. The ergonomic construction of the machine in the new Stealth design also reflects the principle that DMG MORI has been pursuing and optimising continuously for many years, namely making work easier for the user by ensuring better accessibility to all key control features. “This will make working with the machine more efficient in the long term.”

Source: DMG MORI