LASERTEC 65 DED hybrid 2nd Generation
The next Era of Metal Additive Manufacturing!
Max. X-axis travel
735 mm
28.9 in.
Max. Y-axis travel
650 mm
25.6 in.
Max. Z-axis travel
560 mm
22 in.
Max. laser power
3000 W
3000 W
Max. workpiece weight
600 kg
1322.8 lbs.
Highlights
Technology integration at its best - 6 processes in one machine!
- Milling, turning, grinding, laser pre-heating, additive manufacturing and DMG MORI scan3D integrated in one single machine
- 5-axis material deposition with new multiJet nozzle allows homogeneous powder distribution, independent from direction of laser deposition welding
- 170% bigger workpiece vs. 1st Generation - Max. workpiece Ø 840 x 350 mm or Ø 680 x 400 mm → 71 % reduced cost per dm³
- 35 % higher build rate → 47% reduced cost per part
- The right laser source for each application - Infrared and blue laser technology available
Multi-Materials and Gradient Materials in one setup for improved part performance
- Selectively adding materials with more than 60 Rockwell to avoid heat treatment processes
- Improving cooling performance by using copper material in the mold core
- Better materials and improved reliability in the repair process for increased service life
- Improved performance of existing tool designs by adding wear resistant coating
- Material gradients between hard and soft, magnetic and non-magnetic, etc.
AM Assistant for best process reliability and comprehensive traceability
- Integrated thermal imaging camera for observation of the whole work area
--> possibility to control of the interpass temperature and use for laser pre-heating - Automatic calibration of powder mass flow and optical sensor for constant monitoring
- Integrated camera for thermal energy monitoring of the meltpool and closed-loop control of the laser power
- Lateral camera for constant control of the working distance
- AM Evaluator for visualization of the relevant process data (e. g. meltpool size, powder mass flow) as a digital 3D-model as well as in the chronological sequence
New powder management for maximum efficiency and performance
- Three different powder pot sizes available (S = 0,5 l, M = 2,3 l, L = 5 l)
- Increased safety and efficiency due to easier handling and cleaning
- Argon pressurized powder containers during storing
- Integrated pressure leakness check and level sensor (option)
- Automatic dust extraction of powder hopper cabinet
Sample applications
Control & software
CELOS
Integrated digitization of the DMG MORI machines & the shop floor:
- CELOS Machine: APP-based user interface with access to all production-related information
- CELOS Manufacturing: 27 CELOS APPs for the optimal preparation & processing of orders
- Digital Factory: Continuous digital workflows from planning to production & service
Excentric turning and milling
- Superposition of the turning movement by additional X- and Y-traverses
- Applicable for turning and milling
Highlights
Customer Benefits
- Eccentric geometries easy to manufacture
- Exact axis coupling and synchronization in the background
Left : Enter the parameters for the position of the external workpiece area. / Right : Graphical representation of the position within the workpiece.
Efficient Production Package
- Solutions for a safe process and for the efficient use of important machining steps
- Applications: cone cleaning, tool data monitoring, safe withdrawal movement, tapping, deep hole drilling, external thread and spigot milling, internal thread and circular milling, reverse countersink cycle
- 12 stored machining strategies for stock removal, deep hole drilling, Pocket milling machines*
Highlights
Customer Benefits
- Runtime optimization according to individual application
- Safe retraction after program break
- Tool data monitoring
Left : Input mask for universal cycle pocket milling. / Right : Input mask for tapping cycle
Profile Dressing
- Dressing of a profile on the grinding wheel by means of driven profile rollers (negative)
- Full utilisation of AE sensor and integrated dressing strategies
- High time saving as well as high dressing accuracy due to customised dressing wheel development
Highlights
Customer benefits
- Tool and workpiece protection
- Optimized tool process
- Monitoring of the radial and axial spindle load depending on the actual pull-in force
Left: Parameterised input for the production of profiles; Right: Dialogue-guided contour dressing cycle
AM Evaluator
- Visualization of relevant process data (for example, melt pool size, powder mass flow) as a digital 3D model and over time
- Detailed analysis of process data
- Direct comparison of processes for quality assurance
- Creation of part reports
Highlights
Customer Benefits
- Simplification of process development
- Support in quality control
- Enables individual analysis and work up of process-relevant data
- Easy retrofitting of the software within the AM-Analyzer product package (Existing software can still be used)
Left: Detailed analysis of process data using 3D digital models / Right: Overview of process-relevant data and comparison of different data sets
TCC – Tool Control Center
- Chip detection on plan pad and tool cone
- Monitoring of pull-in force
- Cutting edge control in process by symmetry monitoring of the bending moment per cutting edge
- Visualization of the bending moment over time via Graph
Highlights
Customer Benefits
- Tool and workpiece protection
- Optimized tool process
- Monitoring of the radial and axial spindle load depending on the actual pull-in force
Left: NEW; Middle: Wear; Right: Cutting edge break
angularTOOL
- Highest flexibility in the machining of structural components due to variable alignment of the angle head
- Automatic CAD / CAM programming
- Automatic calculation of the TCP and combination with existing control functions
Highlights
Customer Benefits
- Machining of inaccessible positions on the workpiece.
- Savings in non-productive time due to fewer tool changes
- High cost savings due to the use of fewer tools
Left : Tool driven by KSS during drilling operation / Right : Parameter mask for variable angle setting
Maintenance Package i4.0
- Automatic recognition of tool pull-in force for consistently high process stability.
- Predefined cycle for automatic lubrication, every 75h or after 20,000 tool changes.
- Detection of leakage and measuring of usage of pneumatics system.
Highlights
Customer Benefits
- Efficient and timesaving lubrication without operator intervention
- High transparency by displaying the lubrication cycles and the current pull-in force.
- Data recording in combination with the optionally available Condition Analyzer for additional analyzes of air consumption and changes of the pull-in force
Detection of leakage and measuring of usage of pneumatics system.
Simple query of the monitoring parameters and the current pull-in force.
Polygon / Oval-Milling
- Milling of oval and polygonal geometries
- Machining of excentric face polygons possible
- Simple selection of suitable machining strategies
Highlights
Customer benefits
- Simple parametric definition of the shaft-hub connection according to DIN 32711 and DIN 32712
- Enable the machining of small workpieces or those made of long-chipping materials. The perfect complement to Polygon / Oval-Turning.
Left: Selection of the machining strategy; Right: Parametric definition of the geometry on Turn-Mill and Mill-Turn machines
Alternating speed
- Easy to operate through three parameters and without additional sensors
- Avoiding vibrations by means adaptation of the speed
- Application for the main spindle and counter spindle, or for milling machines with FD tables with Direct Drive
Highlights
Customer Benefits
Input of parameters for speed set-point, differential speed and revolution frequency
- No manual intervention by the operator
- Identical repeatability for all components
- Increased process safety for special applications by avoiding vibrations. example, When using long thin drills or for milling parts with critical clamping
Multitool
- Efficient use of multi-tip turning tools with more than one cutting edge on turn & mill
- Several "sister tools" on one main tool holder
Highlights
Customer Benefits
- Reduction of tool change times
- Saves tool magazine space
gearSKIVING 2.0
- Straight and helical external or internal spur gears and splines
- Arrow teeth with tooth offset Turn-mill machines
- Ball-shaped toothing by mathematical transformation of the 6th virtual axis
Highlights
Customer Benefits
- Internal toothing without angular head possible
- Short processing times, 10 x faster than shaping
- Synchronization and tool path controlled by the Cycle
Left : Inside gear profile machining. / Right : Outside gear profile machining.
MPC 2.0 – Machine Protection Control
- Vibration monitoring in the process
- Rapid shutdown in case of a crash
- Manual retraction even in swiveled machining plane
- NEW: Torque monitoring
- New: Recommended with Protection Package for CTX TC machines
Highlights
Customer Benefits
MPC Graph: aktuelle und angelernte Prozesswerte. / MPC Diagnostics: Lagerzustand, Anzahl von Stoß und Crash.
- Avoiding tool breakage
- Increase in machine availability
- Damage reduction
Grinding
Turning
- Turning, milling and grinding in one clamping
- Grinding cycles for internal, external and face grinding as well as dressing cyclesn
- Body-borne sound sensors for start-up and dressing
- Full integration of measurement module for relative and absolute LIVE-Measuring – parallel to main time
Milling
- Better surface quality through integration of the grinding technology
- Grinding cycles for internal, external and face grinding as well as dressing cycles
- Body-borne sound sensors for start-up and dressingn
- 1,300 l Cooling system with integrated centrifugal filter for The filtration of particles > 10 μ
- AKZ nozzle unit optionally available for best possible Flushing of the grinding gap
Highlights
Turning Customer Benefits
- Expansion of the technological limits of the CTX TC
- Surface accuracy < 0.4 μm
- Roundness < 5 μm
- Quality IT5 for ø > 30 mm
Left : External, internal and circular grinding. Grinding with straight / angle or cup disc. / Right : Dressing straight, angled or cup discs simply visualized.
Milling Customer Benefits
- Surface accuracy < 0.4 μ
- Roundness < 5 μ
- Quality 5 for ø < 120 mm
- Quality 4 for ø > 120 mm
Left: Spiral plane grinding or osscillating plane grinding. / Right: Longitudinal grinding.
3D quickSET
Turning
- Measurement and correction of the position of turning and Pivot axes (C4, C3, B)
- Sag compensation possible
- Can be used in combination with standard probes from customers (recommended Renishaw, Blum)
Milling
- Toolkit for checking and correcting the kinematic accuracy of 4- and 5-axis machine configuration
- All head variations and table axes
Highlights
Turning Customer Benefits
- Reliable re-calibration of the machine before a highly precise processing
- Continuous documentation of machine accuracy
- No rejected parts due to unknown Geometric-deviations
Dialogue-guided measurement of the B- and C-axis.
Milling Customer Benefits
- Periodic recalibration of the machine with comprehensive documentation
- Highest kinematic accuracy in self-regulation
Define kinematics head
Interpolation turning 2.0 – turning recessing cycle
- With interpolation turning, the tool cutter follows a circular movement, where the cutter is always oriented towards the center Of the circle.
- Possible for external and internal machining
- Synchronization and tool path controlled by the cycle
- NEW: in version 2.0 complex turning contours are possible (currently only available on the DMU 50, other machine types will follow)
Highlights
Customer benefits
- Easy manufacturing of sealing surfaces where milling operation might not be possible.
- Complete component processing in one clamping possible
- Reduced investment costs for tools
DMG MORI gearMILL
- Productive complete processing
- Cost-effective gear cutting on standard machine with standard tools
- Flexible for different gear geometries
- Quality inspection in the process
Highlights
Customer Benefits
- Program creation based on blank drawings and gear data
- Optimization of workpiece orientation e.g. after heat treatment
- Interface for coordinate measuring device (Klingenberg, Leitz, Zeiss)
Left : Input of the gear parameters for the geometry calculation of a spur gear. / Right : Grafische Betrachtung des Abwälzverfahrens.
Application Tuning Cycle
- Process-oriented adjustment of the feed rate n relation to the table loading
- Minimization of machining time with maximization of the component quality
- NEW: Now also available for CTX TC. Ideal machining result with the highest machine dynamics*
*without consideration of feed weight
Highlights
Customer Benefits
- User friendly setting of the machine dynamics with included DMG MORI knowhow
- Time saving in roughing
- High surface finish during finishing
Left : ATC 2.0 – Milling: Consideration of table loading. / Right : ATC – Turning: for CTX TC for easy adjustment of the machine dynamics.
L-Measuring probe packet
- Measurement of webs and grooves on components
- Measurement of diameter in difficult to access places
- Available with manual and retractable Calibration unit Package content
- L-Measuring probe according to Customer-specific design
Highlights
Customer Benefits
- Flexible application possibilities
- In process measurement
Left : Semi-automatic Measurement solution. / Right : Automatic measurement solution.
Tilted Measuring Cycle
- Measuring with tilted tool axis
- Dialog-guided programming of the measuring cycles
- Positioning of the measuring points with rotary axis
Highlights
Customer Benefits
- Increase in component accuracy
- Reduction of set-up time
- Collision-free measuring thanks to tilted tool axis possible
- Further processing of the measurement results
Left : 1. circumferential measurement, 2. alignment surface, 3. alignment hole / Right : Dialog-guided programming
VCS Complete
- Geometric fingerprint of the machine Volumetric calibration at the touch of a button
- Detection and compensation of geometrical, positioning and angular errors of all axes
- Easy handling and implementation by the customer directly at the machine
Highlights
Customer Benefits
- Regular compensation of the machine geometry over the entire life cycle of the machine
- Dialogue-led operation for easy and fast handling
- Data recording for further analysis
Possible accuracy deviation without VCS-Complete.
gearQUALITY
- Non-contact measurement with the laser scanner
- Measurement and evaluation of gears according to common standards analog to coordinate measuring machines
- Fast measurement with max. 70,000 points / sec. or up to 200,000 points / sec. depending on the laser source
Highlights
Customer Benefits
- Technology and measurement system integration eliminate unnecessary handling of components
- High flexibility in gear measurement and reduction of reaction times during process start-up
- Measurement of gear teeth and scanning of free-form surfaces possible
Left : Simulation of the generated measurement program / Right : Evaluation mask with color-coded result display
Service & training
Downloads & Technical Data
Technology Data
Max. laser power
3000 W
3000 W
Workpiece
Max. workpiece weight
600 kg
1322.8 lbs.
Clearance
Max. X-axis travel
735 mm
28.9 in.
Max. Y-axis travel
650 mm
25.6 in.
Max. Z-axis travel
560 mm
22 in.