Four Complete Process Chains for Powder Bed, Powder Nozzle Technology

DMG MORI offers four complete process chains for additive processes using powder bed or powder nozzle technology. For these solutions, DMG MORI combines its LASERTEC 3D models and LASERTEC 30 SLM 2nd generation models with conventional CNC machines for a single source solution. The completely redesigned LASERTEC 30 SLM 2nd features user-friendly Stealth design, increased process autonomy and a high level of work safety.

DMG MORI's LASERTEC 3D hybrid/LASERTEC 3D solutions feature directed energy deposition (DED) using the powder nozzle technique. The LASERTEC 30 SLM 2nd Generation offers two process chains with additive manufacturing (AM) in the powder bed. Additional features:

• Generative manufacturing in the powder bed with volumes of 11.8" x 11.8" x 11.8"
• Fast material exchange in less than two hours with the rePLUG powder module system
• CELOS: Consistent software solution from CAM programming up to machine control
• Open system: Individual adjustment of all process parameters and unrestricted selection of the material supplier.

Potential of AM

The quality of workpieces produced with additive methods is increasing, as is machining speed. This has resulted in consistently positive forecasts: AM is expected to grow by 20% to 30% 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," explained Patrick Diederich, responsible for AM at DMG MORI.

Diederich added, "If AM 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 be aware of the possibilities offered by AM, 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 already combined laser deposition welding and metalcutting machining in the LASERTEC 3D hybrid series. In addition to establishing and expanding the digital process chain, DMG MORI has also developed technology to become a full-liner in AM. While the LASERTEC 65 3D is geared solely towards laser deposition welding as a complement to existing machining centers 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. With the combination of AM technologies with conventional CNC machines, DMG MORI has realized four individual needs-based process chains.

LASERTEC 3D Hybrid

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 combines AM 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 o19.7" x 15.7". The LASERTEC 4300 3D hybrid enables 6-sided turn and mill operations for workpieces with sizes up to o26" x 59". 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

A second process chain based on the powder nozzle includes the compact LASERTEC 65 3D for 5-axis laser deposition welding and a machining center for final finishing of the additively manufactured components. This makes the LASERTEC 65 3D a suitable addition to the machines already installed on the shop floor, a combination that allows optimum utilization of production capacity. With travel paths of 29" x 25.6" x 22", the work area of the LASERTEC 65 3D is around 40% larger than the hybrid version and its footprint is about 45% 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 build process in the two process chains with the powder nozzle, a capability that can give parts special properties," added Diederich.

LASERTEC 30 SLM 2nd Generation

DMG MORI offers the LASERTEC 30 SLM 2nd Generation for AM in the powder bed (selective laser melting). The second generation of the machine has a 11.8" x 11.8" x 11.8" construction volume and features the new Stealth design that offers enhanced user comfort. Two process chains can be realized with powder bed technology: workpieces produced by means of AM can be finished to the required surface quality on a milling machine, such as the 5-axis DMU 50 3rd Generation. Secondly, the LASERTEC 30 SLM 2nd Generation can finish previously milled base plates and bases without any need for support structures.

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

One particular highlight of LASERTEC 30 SLM 2nd Generation 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," explained 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 optimizing 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."

For more information contact:

DMG MORI - Americas Headquarters

2400 Huntington Blvd.

Hoffman Estates, IL 60192

847-593-5400

Service Hotline:

855-DMG-MORI (364-6674)

info@dmgmori.com

www.us.dmgmori.com