05/15/2019|Chicago Innovation Days 2019 - Additive Manufacturing Excellence Center

Bundled competence at the Additive Manufacturing Excellence Center

DMG MORI develops integral processes linked with the topic of additive manufacturing on the LASERTEC 3D, LASERTEC 3D hybrid, and LASERTEC SLM machines at its ADDITIVE MANUFACTURING Excellence Center in Chicago.

  • Five DMG MORI Excellence Center worldwide
  • AM Consulting for fast technology introduction
  • Unique: Four process chains with ADDITIVE MANUFACTURING and machining from a single source.
  • LASERTEC 3D hybrid / LASERTEC 3D:
    • Success on the market since 2013 with laser deposition welding using the powder nozzle technique
    • Multi-material applications and graded materials in one component
    • LASERTEC 3D hybrid: Finished part in a single setup
    • LASERTEC 30 SLM 2nd Generation: Additive manufacturing in a powder bed with a 300 x 300 x 300 mm build volume
    • LASERTEC 12 SLM: Four-times more accurate than the industrial standard
    • Open system for individual adaptation of all process parameters and free choice of material manufacturers
    • OPTOMET as an intelligent software for calculating all process parameters
  • CELOS: Integral software solution from CAM programming through to machine control
DMG MORI realizes pioneering additive manufacturing solutions involving powder bed and powder nozzle methods.

ADDITIVE MANUFACTURING has long proven its enormous potential and is expected to grow in a high double-digit range. DMG MORI has already been operating successfully on the market for ADDITIVE MANUFACTURING. As a global full-liner with over 20 years of experience in the ADDITIVE MANUFACTURING of metal parts, DMG MORI represents the most important generative machining processes under one roof and ranks as a full-service provider in both the additive production of metallic components and metal cutting finishing. DMG MORI has five ADDITIVE MANUFACTURING Excellence Centers (AMEC) worldwide. The DMG MORI experts at the AMEC in Chicago design and realize pioneering additive manufacturing solutions involving powder bed and powder nozzle methods.

Additive manufacturing is one of the fastest growing technologies, with an annual growth of between 20 and 30 percent expected in the next few years. DMG MORI has supported and advanced this development since 2013, especially in the field of metallic 3D printing. Virtually unlimited freedom of design, resource-saving use of materials and the increasing productivity of additive processes are all proof of its enormous potential. The manifold possibilities of this young technology are increasingly finding their way into development and design, a trend supported by DMG MORI in its North American ADDITIVE MANUFACTURING Excellence Center in Chicago. Innovative machines for additive manufacturing as well as conventional machining, a modern measuring laboratory and a lab for metallurgical testing provide the ideal working conditions for the experts at the center​​​​​​​.

AM Consulting for fast technology introduction

With AM Consulting the DMG MORI pursues the goal of supporting companies in building up the necessary knowhow and establishing the process chains linked with the LASERTEC 3D, LASERTEC 3D hybrid, and LASERTEC SLM series.

Based on the LASERTEC 3D, LASERTEC 3D hybrid, and LASERTEC SLM machines built in Iga, Japan, as well as in Bielefeld and Pfronten, Germany specialists at the AMEC create individual manufacturing solutions with the powder nozzle or in the powder bed. The potential of this technology is already recognized in many companies, but often they do not have the necessary knowledge.

With its new consulting approach, DMG MORI pursues the goal of supporting companies in building up the necessary knowhow and establishing the process chains linked with the LASERTEC 3D, LASERTEC 3D hybrid, and LASERTEC SLM series. The consultancy portfolio encompasses services along the entire process chain of additive manufacturing, including the AM Quick Check as the perfect introduction to exploiting this potential.

Four process chains with ADDITIVE MANUFACTURING and machining from a single source

With their broadly diversified machine portfolio in both machining and ADDITIVE MANUFACTURING DMG MORI approaches the topic holistically. 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. As the most widely used exponent in this series, the LASERTEC 65 3D hybrid is ideally suited for the additive manufacture of complex prototypes and small series parts, for the repair and coating of components. Next comes the LASERTEC 65 3D, which is geared solely towards laser deposition welding as a complement to existing machining centers on the shop floor. The LASERTEC SLM series 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 realized four individual needs-based process chains.

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 19.68 x 15.74 inches. The LASERTEC 4300 3D hybrid enables 6-sided turn & mill operations for workpieces with sizes up to 25.98 x 59.05 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 machines already installed on the shop floor ensuring optimum utilization of production capacity. With travel paths of 28.93 x 25.59 x 22.04 inches 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.

LASERTEC SLM: Two process chains with additive manufacturing in the powder bed

The flexible rePLUG powder module enables material change in less than two hours.

DMG MORI offers the LASERTEC SLM series for additive manufacturing in the powder bed (Selective Laser Melting). The LASERTEC 30 SLM 2nd Generation has a 11.81 x 11.81 x 11.81 inches build volume and with its stealth design offers optimum user comfort, while the new LASERTEC 12 SLM excels with its high above-average accuracy. With a focal diameter of just 35 µm, it is four-times more accurate than the current industrial standard.

This allows a significantly finer resolution of the structures, thus enabling far thinner wall thicknesses. Standing at 4.92 x 4.92 x 7.87 inches the build volume of the powder bed machine is unique for this precision class.

In the market of selective laser melting both models convince with flexibility, productivity, and process security. One of the highlights is the flexible powder module rePLUG. It allows changing materials in less than two hours. The closed powder circuit guarantees a high degree of safety during work and process autonomy. The ergonomic stealth design of both machines additionally reflects what DMG MORI has been pursuing continuously for many years. Work is supposed to become easier for users by a better accessibility of important components. This also makes work more efficient in the long term.

Two process chains can be realized 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, the LASERTEC SLM machines can finish previously milled base plates and bodies without any need for support structures.

The integral software solution for CAM programming and machine control CELOS completes the process chains with the LASERTEC SLM series. The coordinated and uniform user interface enables parts to be programmed externally with minimum time expenditure and transferred to the machine. 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 SLM series enables individual adjustment of all machine settings and process parameters, right through to include an unlimited choice of material manufacturers.

OPTOMET – first time right: Intelligent control of all process parameters

OPTOMET calculates the optimum process parameter automatically, makes programming easier and results in significantly improved surface qualities and reproducible material properties.

With a share of 30 percent in the Indian software developer INTECH DMG MORI has gained access to the key software and technological expertise for generative production. As a pioneer in the field of 3D print in India, the company has specialized in ADDITIVE MANUFACTURING and the related software solutions – including the artificial intelligence in this field. A first result of this collaboration is the new OPTOMET software, which INTECH offers for the LASERTEC SLM series from DMG MORI. It has self-adjusting and learning algorithms that calculate the required parameters of the SLM process in advance within minutes. This means layer thicknesses, for example, can be calculated freely, which in turn enables a faster and therefore more productive build. OPTOMET also has a material database that allows users to use material from all manufacturers without having to test them in advance.

The open system also allows independent expansion of the database using the customer’s own experiments. OPTOMET is also able to adjust parameters in a way that material properties, such as hardness, porosity and elasticity, can be changed or optimized.

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