DMG Mori has continuously expanded its additive manufacturing offering since 2013 - initially in the field of laser deposition welding using powder nozzles on the Lasertec 3D and Lasertec 3D hybrid machines. The expansion to include the powder bed process and thus also the step towards becoming a global full-service provider in the additive manufacturing of metallic workpieces followed in 2017 with the acquisition of Realizer GmbH. The portfolio here includes the Lasertec 30 SLM 2nd Generation and the Lasertec 12 SLM. Both models stand out with their innovative powder handling - the rePlug powder module enables a material change in less than two hours - and the software solutions with Celos and Optomet. The latter enables simple adjustment of all parameters within a few minutes. The DMG Mori Academy completes the additive manufacturing offering with AM Consulting for rapid technology introduction for new users of these manufacturing processes.

"Thanks to additive manufacturing technologies, product developers and designers have completely new design options when conventional processes reach their limits or are simply too expensive," explains Mathias Wolpiansky, Managing Director of Realizer. Especially as a supplement to conventional manufacturing methods, the processes with powder nozzles or in a powder bed are sensible and promising alternatives in the manufacturing process.

Process thinking is a priority at DMG Mori, because with its wide-ranging machine portfolio in both machining and additive manufacturing, the machine tool manufacturer thinks holistically, as Wolpiansky continues: "Economical use of additive manufacturing technologies requires sensible integration into existing production systems and process chains." Only then can the step from prototype and small series production to series production succeed.

Two process chains with additive manufacturing in the powder bed

DMG Mori offers the Lasertec 30 SLM 2nd Generation for additive manufacturing in the powder bed (selective laser melting). The second generation of the machine has an installation space of 300 mm × 300 mm × 300 mm and its new stealth design offers a high level of operating convenience. Two process chains can be realized with the powder bed technology: Firstly, users can post-process additively manufactured workpieces on a milling machine such as the 5-axis DMU 50 3rd Generation with the required surface quality, and secondly, the Lasertec 30 SLM 2nd Generation can finish previously milled base plates or bodies in the powder bed completely without support structures.

Four times more accurate than the industry standard

The latest model in the Lasertec SLM series is the Lasertec 12 SLM. It is characterized by its above-average accuracy. "With a focus diameter of just 35 µm, it is four times more accurate than the current industry standard," compares Florian Feucht, Head of Sales and Application Technology at Realizer. This allows a much finer resolution of the structures. "The result is significantly thinner wall thicknesses." At the same time, the powder bed machine offers a construction volume of 125 mm × 125 mm × 200 mm, which is unique for this precision class.

Occupational safety, process autonomy and ergonomics in one package

In the market for additive systems for selective laser melting, both Lasertec SLM machines impress with their flexibility, productivity and process reliability. One highlight is the flexible rePlug powder module, which can be used on the Lasertec 12 SLM and the Lasertec 30 SLM 2nd Generation. "It enables a material change in less than two hours. The closed powder circuit ensures a high degree of work safety and process autonomy," explains Wolpiansky. The ergonomic design of the machine in the new stealth design also reflects what DMG Mori has been continuously pursuing and optimizing for many years. The aim is to make operation easier for the user by making important elements even more accessible: "This makes working on the machines more efficient in the long term."

As an integrated software solution for CAM programming and machine control, Celos rounds off the process chains with the Lasertec SLM series. "Thanks to the coordinated and uniform user interface, components can be programmed externally and transferred to the machine in a minimum of time," adds Feucht. Thanks to the efficient flow of information and intuitive operation, Celos guarantees optimum processes in the pre- and post-processing of additively manufactured components. The open system of the Lasertec SLM series enables individual adaptation of all machine settings and process parameters, including an unrestricted choice of material manufacturer.

Intelligent control of all process parameters

With a 30 percent stake in the Indian software developer Intech, DMG Mori is gaining access to important software and technology expertise for additive manufacturing. As a pioneer in the field of 3D printing in India, the company specializes in additive manufacturing and related software solutions - including artificial intelligence for this area. A first result of this collaboration is the new Optomet software that Intech offers for DMG Mori's Lasertec SLM series. "Optomet has self-adapting and learning algorithms that calculate all the necessary parameters for the SLM process in advance within minutes," says Wolpiansky, describing how it works. This allows layer thicknesses, for example, to be calculated freely. "This in turn speeds up the build and makes the process more productive." A material database integrated into Optomet allows users to use materials from all manufacturers without having to test them beforehand. The open system also allows users to expand this database independently through their own experiments. The software is also able to adjust parameters so that material properties such as hardness, porosity and elasticity can be changed or optimized.

Four process chains in additive manufacturing

Two process chains can be realized with powder bed technology: On the one hand, users can finish additively manufactured workpieces on a milling machine such as the 5-axis DMU 50 3rd Generation with the required surface quality; on the other hand, the models in the Lasertec SLM series can finish previously milled base plates or bodies in the powder bed without any support structures - together with the powder nozzle technology, DMG Mori can therefore realize a total of four process chains.

The Lasertec 65 3D hybrid combines powder nozzle and 5-axis simultaneous milling in one clamping, while the Lasertec 3D for pure laser deposition welding (like the Lasertec SLM series) is the ideal addition to an existing machine park.