Additive manufacturing for series production

With future-oriented solutions and integrated processes, the machine tool manufacturer ensures that additive manufacturing can also set new standards in series production - both in laser deposition welding on the Lasertec DED hybrid models and with the powder bed machines from the Lasertec SLM series. DMG Mori is thus underlining its role as an innovation leader and providing an outlook on the role that additive manufacturing will play in the Machining Transformation (MX) in the future.

6-in-1 process for efficient series production

DMG Mori realizes series production on the Lasertec DED hybrid machines with an integrated 6-in-1 process. It includes milling, turning and grinding on the one hand and preheating, additive manufacturing using a powder nozzle and a 3D scan on the other. As part of its Machining Transformation (MX), DMG Mori is thus consistently focusing on process integration in a single clamping operation. This reduces throughput times because components do not have to be cast, transported and reworked first. The advantages are obvious: switching between subtractive and additive technologies allows the creation of complex geometries and multi-material applications can be equipped with tailored properties, such as better wear or corrosion protection and increased resistance to chemicals. In addition, tool inserts, for example, can be repaired cost-effectively. Additively manufactured components often have a longer service life and reduced maintenance times, significantly increasing their availability. At the same time, throughput times are massively reduced.

As the latest part of this process chain, preheating minimizes stresses and prevents cracks between the base and welding material, which improves the mechanical properties. A tool-changeable 3D laser scanner enables non-contact detection and precise quality control through false color display. The optional use of blue lasers expands the range of materials to include highly reflective metals such as copper and enables graded material transitions for highly functional components. At the end of the process chain is precise finishing on the same machine. All steps - from preheating, scanning and material application through to machining - can be flexibly combined and repeated as required. This turns a complex multi-stage process into a continuous, highly automated workflow that proves the suitability of hybrid manufacturing for series production in practice.

Consistent productivity in the powder bed

In the field of powder bed machines, DMG Mori is setting new standards in efficiency, precision and productivity with the Lasertec 30 SLM 3rd generation. A key innovation is the exchangeable build container, which eliminates one of the biggest bottlenecks in metal 3D printing: the long cooling times after build jobs. Finished containers can be removed without waiting time after completion and replaced with prepared containers - the machine remains productive almost without interruption. Set-up times are also significantly reduced, as the preparation of the construction panels will be carried out externally in future. This not only eliminates the need to repeatedly flood the chamber with inert gas, but also significantly reduces the consumption of shielding gas. An integrated lid system also increases safety and maintains the protective atmosphere between two jobs, which means that powder management and material handling remain possible under inert gas conditions. The machine also impresses with its robust design. The stable cast frame reduces thermal influences, as does the floating process chamber. Active Z-axis compensation stabilizes the layer height, while up to four fully overlapping lasers ensure uniform and productive material processing. With an extended installation space of 325 × 325 × 400 mm, larger or multiple components can be produced in parallel, making the machine attractive for series production. At Formnext, DMG Mori will also be presenting the new rePlug Flex, a simple version of the proven rePLUG powder module. This variant dispenses with the closed powder circuit within the machine. Instead, the material can be changed without an additional powder module - an economical solution, especially for materials that are only used on a small scale.

The Lasertec 30 SLM 3rd generation is easy and intuitive to operate thanks to Celos X with easyAM. Camera monitoring of the powder bed also ensures high component quality while minimizing process interruptions. After each layer, the surface is scanned and analyzed for anomalies. A heat map visualizes possible defects and an evaluation system assigns an "anomaly score" to the respective layer, the graphic display of which enables an immediate check of all layers built so far at a glance. A new feature is the function of projecting layer data of the workpiece onto the respective camera image. This makes it easier to assess whether a detected defect actually has an impact on the component or is limited to non-critical areas. With this combination of stability, productivity and digitalization, the Lasertec 30 SLM 3rd generation marks a major step towards industrially scalable powder bed production. DMG Mori will be demonstrating such a manufacturing process at Formnext using the example of a Matris light robot head.

Exploiting the potential of additive manufacturing

The latest development examples show: DMG Mori realizes innovative processes related to additive manufacturing on both a technological and economic level. The Additive Intelligence consulting unit facilitates entry into this topic with in-house experts. They advise and support customers in exploiting the full potential of AM - from the initial idea to design and series production. In combination with the latest machine developments, hybrid process chains and digital tools, this creates a complete package that gives companies a real competitive advantage. The production of customer parts can also be implemented in this unit. Today, more than 3,000 components are already produced annually for use in Group machines. DMG Mori is thus underlining its role as a partner on the path to the future of manufacturing - and as a driver of sustainable Machining Transformation (MX), which takes additive technologies out of the pioneering phase and into industrial reality.