Complex 3D components with powder nozzle or in the powder bed

With the LASERTEC 65 3D, the LASERTEC 4300 3D and the LASERTEC 30 SLM, DMG MORI now has a comprehensive portfolio in additive manufacturing

DMG MORI is selectively expanding its future technologies: with a majority shareholding of 50.1% in REALIZER GmbH from Borchen, the Group has now strengthened its position in the field of additive manufacturing. DMG MORI already has extensive expertise in the field of laser deposition welding with powder nozzles (laser metal deposition) through SAUER GmbH. The range of machines here comprises the LASERTEC 65 3D and the LASERTEC 4300 3D. The company REALIZER in turn has over 20 years of experience in "Selective Laser Melting" (SLM). With the integration of REALIZER in the product range from SAUER, DMG MORI now offers the key generative manufacturing processes for metallic materials from a single source. The first result of this cooperation is the LASERTEC 30 SLM.

With the new LASERTEC 30 SLM as addition to the already successful LASERTEC 65 3D and LASERTEC 4300 3D, SAUER GmbH and DMG MORI are consolidating their position as the world’s first full-liner in additive manufacturing with both hybrid and selective laser melting machines. “Selective laser melting in a powder bed opens up completely new areas of application for our customers. That is why this is the perfect complement to our LASERTEC 3Dmachines in the field of advanced technologies”, says Christian Thönes, Chairman of the Executive Board of DMG MORI Aktiengesellschaft.

LASERTEC 30 SLM:
Sophisticated components in top quality
The LASERTEC 30 SLM is equipped with a powder bed that has a volume of 300 × 300 × 300 mm. With this method, powder is applied in layers onto the work platform and melted by means of selective exposure. When the melting procedure is finished, the platform is lowered to the amount of the respective layer thickness and the procedure is then repeated with a new layer of powder. The process enables the production of high-precision 3D components with layer thicknesses of 20 to 100 µm depending on the surface quality and build-up rate - and it does so with no great impact on the production costs. Even complex grid and honeycomb structures, which cannot be realised with other methods, can be produced in high quality in this way.

As SLM technology allows the use of different materials, its fields of application range from the automotive and aerospace to the dental and medical industries and on to include tool and mould making. Thanks to a low porosity (0.1 to 0.5 percent), the components made of aluminium, stainless steel alloys, titanium and Inconel excel through extremely good properties similar to those of the basic material. DMG MORI also offers application-specific fibre laser sources of 400 Watt to 1 Kilowatt.

The LASERTEC 30 SLM guarantees efficient and cost-effective production thanks to its low argon consumption of only 70 l/h and integrated powder conditioning that ensures optimum powder handling and reduces the particulate matter formation to a minimum. Moreover, the exchangeable powder module means it takes less than two hours to change the powder. An end-to-end software solution with a uniform user interface from CAD-File (RDesigner) to process control (ROperator) simplifies operation of the LASERTEC 30 SLM.

In order to round off the SLM manufacturing process ideally, DMG MORI also enables subsequent machining on its highly dynamic machining centres from the group portfolio. This way, highest component accuracies and best surface finishes can be achieved on the powerful HSC machines or, in case of advanced materials like Iconel, also on ULTRASONIC models.

LASERTEC 65 3D and LASERTEC 4300 3D:
Additive manufacturing in finished part quality
With the LASERTEC 65 3D, DMG MORI has integrated the generative laser deposition process in a fully-fledged 5-axis milling machine. The LASERTEC 4300 3D combines the procedure with the turn-mill equipment in a large work area of ø 660 x 1,500 mm. These intelligent hybrid solutions combine the flexibility of additive manufacturing with the precision of machining, thus enabling the manufacture of complete components in finished part quality. This laser deposition process uses a deposition process by means of a metal powder nozzle, which enables complete machining without the need of a process chamber and is up to 1 times faster than generation in a powder bed. This is beneficial, as the trend is often towards increasingly individual manufacturing.

Adding to this, components are getting more and more complex. With the LASERTEC 65 3D and the LASERTEC 4300 3D, the production of overhanging contours without a supporting geometry is entirely possible. The latter as turn-mill machine even enables 6-sided complete machining of 3D components. The combination of laser deposition welding with machining on one machine opens up completely new application and geometry possibilities. Large components in particular can be produced cost effectively with these hybrid solutions. Flexible switching between laser machining and milling also enables component segments which are no longer accessible on the finished part to be machined directly.

With the LASERTEC 65 3D , DMG MORI has already gone one step further and offers ULTRASONIC grinding as an option. This way, Inconel components – for example, the blades of a drill bit – can also be built up generatively here and then finished in the required quality. For this purpose, only the ULTRASONIC grinding tool is inserted into the standard spindle via an automatic tool changer. With the combination of technologies, DMG MORI can virtually double productivity. After all, there is no longer any need for eroding on the one hand while on the other the service life of tools is noticeably increased due to the reduced process forces.

Highlights LASERTEC 30 SLM

Generative manufacturing in the powder bed with volumes of 300 × 300 × 300 mm
Application-specific fibre laser sources of 400 Watt to 1 Kilowatt
High-precision build-up of 3D components with layer thicknesses of 20 to 100 μm
Integral powder conditioning system for even more efficiency and material utilisation and minimisation of particulate matter formation
Optimum process chain for subsequent machining on DMG MORI machines – for highest component accuracy and best surface finishes

Highlights of the LASERTEC 65 3D

Best surface finishes as well as component precision
Laser deposition welding with powder nozzle: 10 times faster compared to powder bed processes
3D components with diameters up to ø 500 mm without any supporting geometry, even with overhanging contours
Process-independent software module
Defined laser deposition even on milled surfaces

Highlights of the LASERTEC 4300 3D

Unique: Laser deposition welding and 6-sided Turn & Mill complete machining
Generation and machining of workpieces up to 660 × 1,500 mm / 1,500 kg
Precise NC-controlled deposition welding also of different material combinations, e.g. copper on Inconel for the aerospace industry
10 x faster material deposition compared to powder bed processes or galvanising

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