05/10/2018|Innovation Days Chicago 2018 - ADDITIVE MANUFACTURING

Global full-solution provider for additive manufacturing

DMG MORI is advancing this future-oriented technology with the consistent development of additive manufacturing in both powder nozzle and powder bed techniques.

  • Unique: Three process chains in ADDITIVE MANUFACTURING and metal cutting from a single source
  • 20 years of experience in laser technology and SLM technology
  • Deposition-to-finishing competence in the field of additive metal machining
  • Powder bed (SLM) and powder nozzle (DED) under one roof for all metallic materials and geometries
  • LASERTEC 3D hybrid / LASERTEC 3D: Success on the market with directed energy deposition (DED) using the powder nozzle technique
  • LASERTEC SLM: revolution in powder bed technology
  • 5-axis complete machining and turning of up to 6 sides in a single setup
  • Five Additive Manufacturing Excellence Centers worldwide: Bielefeld, Pfronten, Chicago, Tokyo, Shanghai
  • Comprehensive consultation for material selection and parameter definition as the basis of high process reliability
  • Increase in productivity through linking additive, hybrid, and subtractive technologies
  • Automated processes for minimizing idle times
  • Digitization for more flexibility in production

Additive manufacturing has long proven its enormous potential in recent times. Annual growth rates in today’s still small market are over 30 percent, even considerably higher in part where metallic components are concerned. According to the latest forecasts, additive manufacturing is expected to grow by 20 to 50 percent by the year 2020. In other words, the market will grow by a factor of 2 to 4. It is therefore only logical that as a technology leader DMG MORI will consistently advance in this area. DMG MORI has already been operating successfully on the market for ADDITIVE MANUFACTURING since 2013 with directed energy deposition using powder nozzle technology. With its deposition-to-finishing competence, DMG MORI presents the most important generative machining processes under one roof and ranks as a full-solution provider in both the additive production of metallic components and metal cutting.

Future-oriented and highly competitive markets are always on the lookout for innovative and cost-effective production opportunities. They are therefore often seen as the drivers of new technologies. So it is not surprising that additive manufacturing is gradually being adopted in all markets. The USA, Europe, Korea and Japan in particular have become established here as core markets. Aircraft manufacturers see great potential in the chance to reduce the weight of components. Additive manufacturing is already wide spread in medical technology production and dental laboratories, because it offers economical solutions for many different applications, even for batch size 1.

Unique process chains for finish machining additive components

The build volume of the LASERTEC 30 SLM is 12 x 12 x 12 inches with a maximum loading capacity of 441 lbs. Powder changeover takes just two hours.

The LASERTEC 3D and LASERTEC SLM series constitute the cornerstone of DMG MORI’s strategic orientation in the latest age of technology. While the LASERTEC 3D hybrid successfully combines direct energy deposition with a powder nozzle and 5-axis milling, the LASERTEC SLM series stands for selective laser melting in a powder bed. “Both manufacturing technologies complement each other ideally in our product range,” explains Patrick Diederich, responsible for the Advanced Technologies division. The powder bed process in particular is of great importance: “The technology has a market share of 80 percent in the additive manufacturing of metallic components. Many customers are pursuing both because the technologies complement each other.”


LASERTEC 3D hybrid: Perfect additive and metal-cutting combination

LASERTEC 65 3D hybrid
The LASERTEC 65 3D hybrid combines directed energy deposition with 5-axis milling in a single setup.

DMG MORI already revolutionized the additive manufacturing of metal components four years ago by combining directed energy deposition and machining on a single machine. This concept is used in both the 5-axis LASERTEC 65 3D hybrid and the LASERTEC 4300 3D hybrid. It combines directed energy deposition and 6-sided turn-mill machining. Both machines are designed for the manufacturer of comparatively large components such as complex turbine components. Work areas of ø 20 x 16 inches in the case of the LASERTEC 65 3D hybrid and ø 26 x 51 inches for the LASERTEC 4300 3D hybrid speak for themselves as do workpiece weights of up to 1323 lbs. or 1984 lbs.

What is revolutionary about the machine concept of the LASERTEC 3D hybrid series is the diversity of the possible applications. Directed energy deposition and milling or turn-mill operations in a single setup mean first of all that workpieces can be produced with finished part quality. Whereby the powder nozzle and milling head can also be changed over at any time. “Especially where complex geometries are concerned, areas can be machined that would no longer be accessible on the finished part,” points out Patrick Diederich. Such applications are called for in particular in the aerospace, energy technology and die and mold industries. “Added to this is the option of producing innovative components from two or more materials and even graded materials by using different powder nozzles.”

Innovative components from two or more materials and even graded materials in sandwich structures can be produced on the LASERTEC 65 3D / LASERTEC 65 3D hybrid.

LASERTEC SLM: Offensive from the powder bed

powder bed technique
With the powder bed technique very small, highly complex parts can be manufactured by means of selective laser melting

With the powder bed technique very small, highly complex parts can be manufactured by means of selective laser melting. Like the LASERTEC 3D machines, the LASERTEC 30 SLM enables the flexible use of different materials, while an intelligent powder module concept allows the change of material in under two hours.

DMG MORI relies on its own machining centers for the finishing of workpieces from the powder bed. “The key issue here is an expedient linking of the different technologies. With the LASERTEC 30 SLM we have brought powder bed technology out of the laboratory environment and into the sphere of industrial production. This machine is an ‘enabler’ of technology,” says Florian Feucht, Head of Sales and Application at REALIZER GmbH. This applies to both the hardware and the software. “Integral processes are the overarching goal.”

CELOS in additive manufacturing

Against the backdrop of integrated processes, Industry 4.0 is of course an ever-present topic. DMG MORI is actively advancing the topic with its “Path of Digitization” and its intelligent software solutions. These also include the intuitive user interface CELOS®. This is already used for the LASERTEC 3D hybrid machines. Future versions of CELOS will include RDesigner, an industrial solution created by REALIZER for the LASERTEC 30 SLM. “The capture and management of data and the utilization of user-friendly apps offer a great opportunity for supporting work preparation and the production processes”, claims Patrick Diederich. This means digitization has a great impact on capacity utilization and on the flexibility of production. “Digitization and additive manufacturing go hand-in-hand and will tap great potential,” says Patrick Diederich optimistically.

A leader of technology with global presence and industrial maturity

DMG MORI also looks optimistically into the future with additive manufacturing. On one hand, the machine tool manufacturer underpins its expertise in this field in DMG MORI Additive Manufacturing Excellence Centers spread around the world in Bielefeld, Pfronten, Tokyo, Shanghai and Chicago. The responsible experts there are involved in customer projects very early on in the development phase, so they can gain knowledge that they then incorporate in the construction of the machines and components. On the other hand, DMG MORI confirms its great ambitions for the focus topic with further technology developments.

DMG MORI views additive manufacturing as a complement to traditional production methods. “With the LASERTEC 30 SLM from Bielefeld, the LASERTEC 4300 from IGA, and the LASERTEC 65 3D hybrid from Pfronten, the DMG MORI Additive Manufacturing Excellence Center in Chicago has several machines at its disposal with which it offers customers highly qualified training in the topic of ADDITIVE MANUFACTURING,” says Dr. Greg Hyatt, CTO of DMG MORI Advanced Solutions. Another aspect is the design of components: “Design engineers, too, will increasingly recognize the potential of additive manufacturing and will integrate the technology in their work. After all, they will be able to realize workpieces in a way they would not be able to produce with conventional manufacturing processes.” DMG MORI will soon also be offering training courses in this field.

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