LASERTEC 30 SLM 2 nd Gen. LASERTEC 65 3D LASERTEC 65 3D hybrid LASERTEC 4300 3D hybrid ADDITIVE TECHNOLOGIES ADDITIVE MANUFACTURING Reinvent your Metal Production NEU DMGMORI.COM
Product Line SLM Machines Powder Nozzle Machines Excellence Centre LASERTEC SLM Additive Manufacturing through selective laser melting (SLM) in the powder bed Selective Laser Melting: Powder Bed LASERTEC 3D Laser deposition welding using a coaxial powder nozzle 02 Laser Deposition Welding: Powder Nozzle LASERTEC 3D hybrid The combination of two technologies on one machine. Combining laser deposition welding using a coaxial powder nozzle, with a 5-axis milling machine or a multi-axis turning machine for finishing AM parts Laser Deposition Welding: Powder Nozzle with Milling & Turning
ADDITIVE TECHNOLOGIES Global full-liner for additive manufacturing + Unique: Four process chains in ADDITIVE MANUFACTURING and metal cutting finishing from a single source + 20 years experience in laser technology and SLM technology + End-to-end competence in the field of additive metal machining + Powder bed (SLM) and powder nozzle (LDW) under one roof for all metallic materials and geometries + LASERTEC 3D hybrid / LASERTEC 3D: Successful on the market with laser deposition welding via powder nozzle + LASERTEC SLM: Pioneer in powder bed technology + Comprehensive consulting services and training e. g. for construction, material selection and the definition of process parameters 03 WORLDWIDE SERVICE 5 Additive Manufacturing Excellence Centres worldwide AMEC Bielefeld, Germany AMEC Pfronten, Germany AMEC Shanghai, China AMEC Tokyo, Japan AMEC Chicago, USA
Product Line SLM Machines Powder Nozzle Machines Excellence Centre ADDITIVE TECHNOLOGIES Unique Product Range Additive Manufacturing with powder nozzle and powder bed from a single supplier Laser Deposition Welding combined with milling LASERTEC 65 3D hybrid 04 + Additive manufacturing with integrated 5-axis milling in finished part quality + Max. workpiece dimensions: ø 500 400 mm, 600 kg Laser Deposition Welding combined with turning / milling LASERTEC 4300 3D hybrid + Additive manufacturing with integrated 6-sided turn & mill complete machining + Max. workpiece dimensions: ø 660 1,500 mm, 1,700 kg
Selective Laser Melting (SLM) LASERTEC 30 SLM 2 nd Gen. + Additive manufacturing in powder bed with integrated powder recycling + Max. workpiece dimensions: 300 300 300 mm 05 Laser Deposition Welding LASERTEC 65 3D + Special machine for additive manufacturing + First dedicated powder nozzle machine based on a CNC machine + Max. workpiece dimensions: ø 650 560 mm, 600 kg
Product Line SLM Machines Powder Nozzle Machines Excellence Centre GLOBAL FULL-LINER FOR ADDITIVE MANUFACTURING Four process chains for additive complete machining Laser Deposition Welding 3D hybrid SIEMENS NX ADDITIVE / HYBRID 3D ADDITIVE MANUFACTURING WITH POWDER NOZZLE Part size max. max. ø 650 mm, height 560 mm 06 Selective Laser Melting (SLM) SLM ADDITIVE MANUFACTURING IN POWDER BED Part size max. max. 300 300 300 mm SLM METAL-CUTTING MACHINING CELOS
FINISHED PART ADDITIVE MANUFACTURING WITH POWDER NOZZLE COMBINED WITH: MILLING LASERTEC 65 3D hybrid: Part size max.: ø 500 mm, height 400 mm TURN & MILL LASERTEC 4300 3D hybrid: Part size max.: ø 660 mm, length 1,500 mm METAL-CUTTING MACHINING 07 METAL-CUTTING MACHINING ADDITIVE MANUFACTURING IN POWDER BED Part size max. 300 300 300 mm
Product Line SLM Machines Powder Nozzle Machines Excellence Centre REALIZER GMBH Pioneer of the powder bed process with more than 20 years application experience: Selective Laser Melting FUNCTIONAL PRINCIPLE: BUILDING A PART LAYER BY LAYER 1 Applying a layer of powder 2 Selectively melting the powder using laser light 3 After melting, the platform is lowered by the respective thickness of the layer 4 Applying a new powder layer PROCESS ROOM 08 Shield gas volume flow optic Shield gas volume flow Laserbeam Recoater Shield gas volume flow Workpiece Powder overflow Elevator Powder supply 1990 1995 1997 2004 Dr. Matthias Fockele is co-founder of F & S Stereolithografietechnik GmbH, now REALIZER GmbH. In cooperation with the Fraunhofer Institute for Laser Technology (ILT) in Aachen, Germany, F & S begin developing the SLM technology. First patent applications for the SLM technology. Dr. Matthias Fockele establishes REALIZER GmbH in Borchen, Germany.
HIGHLIGHTS + Highly complex components with function integration + Internal close-contoured cooling channels + Topology-optimised components + Simultaneous build-up of different designs + Weight optimisation due to lattice and honeycomb structures Combustion chamber prototype + Functional prototypes made of series materials 09 2017 2018 On 06 / 02 / 2017, DMG MORI takes over 50.1 % from REALIZER and the LASERTEC 30 SLM celebrates its WORLD PREMIERE. DMG MORI increases the proportion of REALIZER to 75.1 % and presents the second generation of the LASERTEC 30 SLM in the middle of 2018. LASERTEC 30 SLM 2 nd Generation Highest process autonomy, maximum work safety and intuitive operation for top component quality and reproducible results.
Product Line SLM Machines Powder Nozzle Machines Excellence Centre SELECTIVE LASER MELTING Applications Automotive Quick and near production quality functional prototypes made from aluminium, titanium or steel. Complex parts with multiple free-form surfaces, as individual items or in small series. Aerospace Customised applications made from aluminium and titanium, e. g. blades with integrated cooling channels and high-efficiency heat exchangers. 10 Dental Custom-fit dental implants such as stages, crowns or bridges made from cobalt chrome or titanium. Medical Implants such as joint or bone prostheses made from titanium. Customised, tailor- made implants. Complex lattice structures, e. g. for hip and knee implants Tool / mould making Production of tool inserts with close-contoured cooling channels. Manufacturing of prototypes and small series
SELECTIVE LASER MELTING New design freedom POWDER NOZZLE BODY LASERTEC 65 3D hybrid 1 Agile product development due to completely digital process chain 2 Significant reduction of production costs due to tool-less production 3 Function integration: Improved cooling due to larger surface 4 Complex geometries almost without restrictions in construction 5 Work preparation: Optimal interaction of parameter optimisation and machine with the in-house developed RDesigner 1 11 6 Integral design by bringing together conventional components, sealing and connection elements 8 7 Lightweight construction: Integrated honeycomb structures 2 8 Function integration: Complex internal channels 7 6 3 5 4
Product Line SLM Machines Powder Nozzle Machines Excellence Centre LASERTEC 30 SLM 2 nd Generation Generative manufacturing in powder bed process HIGHLIGHTS CELOS AS STANDARD + Powder bed with 300 300 300 mm construction volume 12 + High precision building of 3D parts with layer thicknesses between 20 and 100 μm for maximum productivity + Dynamic adjustment of the focus diameter between 70 and 200 µm + Application-specific fibre laser sources from 600 W as standard to 1 kw optional + Optimised shield gas volume flow for highest component quality with minimum Argon consumption < 72 l / hour + Maximum work safety due to closed material cycle and integrated powder recycling + Replaceable powder module replug for contamination-free material exchange < 2 hours + CELOS: Consistent software solution from CAM programming up to machine control Open system: Individual adjustment of all machine settings and process parameters as well as unrestricted selection of the material supplier.
replug RESEARCH Optional powder module, especially developed for the material and process parameter development on the series system. NEW 13
Product Line SLM Machines Powder Nozzle Machines Excellence Centre LASERTEC 30 SLM 2 nd Generation replug The powder module for fast material change HIGHLIGHTS 14 + Automated powder handling and powder storage under inert atmosphere + One material per replug Any expansion of the material range due to modular changing system + Contamination-free change between different materials in < 2 hours + Safe powder handling due to integrated periphery and closed material cycle + Increased efficiency due to integrated powder recycling + High process autonomy due to powerful duo filter system (filter change without process interruption) as well as large powder reservoir (no manual refilling required in the process) 1 Sieving unit 2 Buffer tank Optional: replug RESEARCH The additional powder module, especially developed for the material and process parameter development on the series system. 3 Powder supply process room Powder return process room 4 Main tank 5 Powder transport in the inert gas volumetric flow
MATERIAL CHANGE < 2 h 1 2 15 3 5 4 WIDE RANGE OF AVAILABLE MATERIALS + Aluminium AlSi10Mg0.5 + CoCrMo (ASTM F75) + Inconel 625 / 718 + Stainless steel 1.4404 + Stainless steel 1.4828 + Tool steel 1.2709 + Titanium Ti4 / Ti6Al4V Unrestricted selection of the material supplier!
Product Line SLM Machines Powder Nozzle Machines Excellence Centre CONTROL AND PROGRAMMING CELOS: CAM programming and machine control from one source CELOS ensures an efficient flow of information in production and provides the machine operator with all relevant order information in real-time. Touchscreen and APPs ensure intuitive operation of the machine, while different monitoring tools enable a transparent view of the current process at all times. 16 CELOS APPS RDESIGNER CAM programming MATERIAL MANAGEMENT Management of material data and parameter editor MANUAL CONTROL Machine setup for process preparation JOB CONTROL Machine control JOB HISTORY Job management WATCHER Camera-based process monitoring and documentation of each individual layer STATUS MONITOR Visualisation of the machine status in real time MESSENGER Live status on PC, tablet or smartphone for complete process monitoring NETSERVICE Online error analysis and technical support directly on the machine control SETTINGS Machine settings
RDESIGNER CAM programming + Start with a pure CAD model (STEP, STL) + Orientation / positioning + Support + Slicing + Hatching + Copying + Generation Process Control File Heat Calculation + Advance calculation of mass distribution + Automatic adaptation of all laser parameters for top component quality + Integration in RDesigner 17 JOB CONTROL + At a glance: All relevant machine and job parameters + Camera-based check of the build-up and coating quality + Automatic machine stop at error detection
Product Line SLM Machines Powder Nozzle Machines Excellence Centre SLM PROCESS CHAIN End-to-end competence with integral process understanding from drawing to finished part Additive Manufacturing Milling Highest component accuracy and top surfaces guaranteed Post-processing on milling machines from DMG MORI 18 CAD / CAM ADDITIVE MANUFACTURING IN THE POWDER BED MILLING / FINISHING ON DMU 50 3 rd Gen. FINISHED PART DMU 50 3 rd Gen. HIGHLIGHTS DMU 3 rd Gen. EVEN STRONGER EVEN BETTER + 5-axis machining with up to 20,000 rpm + Swivelling rotary table for 5-axis simultaneous machining + Tool magazine with 30 pockets in the standard and optionally up to 120 magazine pockets + Integrated cooling concept for top long-term precision + Directly-driven ball screw drive for the best possible accuracy + Direct travel measuring system in all axes
CELOS Due to the efficient information flow and the intuitive operation, CELOS stands for optimum process chains in pre- and post-processing of additively produced components. Milling Additive Manufacturing Full flexibility The milling of base plate and base body before the additive manufacturing process makes support structures superfluous and leads directly to the finished part! 19 CAD / CAM MILLING ON DMU 50 3 rd Gen. ADDITIVE MANUFACTURING IN THE POWDER BED FINISHED PART Application example: Basic tibia plateau + Material: Ti6Al4V + Machining time milling: 12 min. / unit DIRECTLY TO THE FINISHED PART! + No post-processing + No support structures + Machining time additive manufacturing: 9 hours (9 parts) + Layer thickness: 50 µm + Dimensions: 75 57 53 mm
Product Line SLM Machines Powder Nozzle Machines Excellence Centre DMG MORI ACADEMY: CONSULTATION FOR ADDITIVE MANUFACTURING Start now and use the full potential of the SLM technology! AM-QUICKCHECK FOR YOUR CONSTRUCTION Consultation and identification of components with additive manufacturing potential. INDIVIDUAL TRAINING ON SITE Basics of additive manufacturing Component selection Component analysis 20 + Technology overview + Materials + Opportunities and challenges + Process chain from design to finishing + Best practices from the industry + Methods for identification of components with AM potential + Sighting of first component ideas from your company + Analysis of components + Rating according to technical and economic attractiveness + Portfolio creation + Concepts for redesign + Roadmap derivation Technical attractiveness low high Powder nozzle holder LASERTEC 65 3D hybrid after redesign for additive manufacturing + Integral design medium + Reduction of production costs + Increased cooling + 60 % lighter + 95 % less components low medium high Economical attractiveness Do not implement AM-Redesign Implement in AM Component / group
Your contact person Dr. Rinje Brandis Head of Consulting Additive Manufacturing DMG MORI Academy GmbH Gildemeisterstraße 60 DE-33689 Bielefeld Tel.: +49 5205 74 2575 Mobile: +49 151 74412703 rinje.brandis@dmgmori.com www.dmgmori.com OPTIMUM ADDITIVE MANUFACTURING CONSTRUCTION WITH TOPOLOGY OPTIMISATION + Cost reduction due to lightweight construction: Reduced material usage due to structure optimisation + Design advantages: Design freedom in the construction process 21 + Unrivalled: Cannot be produced conventionally Lens holder LASERTEC 30 SLM 2 nd Gen. DMG MORI ACADEMY: OUR SERVICES + AM quick check for the identification of your specific additive manufacturing potentials + Redesign of your components for additive manufacturing + Engineering and construction of new components and assemblies + Simulation and topology optimisation + Production of prototypes and small series of your components + Training for management, construction and manufacturing + Consultation from AM strategy to optimisation of your AM production
Product Line SLM Machines Powder Nozzle Machines Excellence Centre LASERTEC 30 SLM 2 nd Gen. Floor plans Front view 2,377 Air outlet 2,015 22 Top view 893 741 2,560 925 869 Filling chiller < 3.0 sqm Power supply Shield gas supply Cooling medium inlet and outlet Cooling medium inlet and outlet Electrical connection Air inlet 610 500 2,673 4,684 910 space for replug-powder Cartridge
LASERTEC 30 SLM 2 nd Gen. Technical data Connection data Connection data Description Value Description Value Electrical connection Building data Main connection (3N / PE) Building volume (X Y Z) 300 300 300 mm Rated voltage 400 V / 230 V ± 10 % Layer thicknesses 20 100 µm Frequency 50 60 Hz Focus diameter 70 200 µm Power consumption 15 kva Laser type Fibre laser Required mains fuse Required short-circuit power Inert gas connection Inert gas 32 A 250 kva Argon Laser power (depending on version) Material 600 1,000 W Tool steel, stainless steel, cobalt chrome alloys, titanium, aluminium, Inconel Purity 4.6 or higher Software CELOS / RDesigner Minimum consumption per build (floods and large parts) Average consumption Min. Pressure Gas connection Network connection 1,000 l 72 l / h 6 bar Connector D 10 mm Integrated powder extraction Integrated screen unit Machine weight Machine replug powder module (without powder) Yes (in replug powder module) Yes (in replug powder module) 1,200 kg 540 kg Connection type RJ-45 Connector 23 Your contact person Your contact person Florian Feucht Head of Sales and Application Jan Riewenherm Product Manager REALIZER GmbH Gildemeisterstraße 60 DE-33689 Bielefeld Tel.: +49 5205 74 3682 Mobile: +49 151 10842329 florian.feucht@dmgmori.com www.dmgmori.com REALIZER GmbH Gildemeisterstraße 60 DE-33689 Bielefeld Tel.: +49 5205 74 3395 Mobile: +49 151 19537344 jan.riewenherm@dmgmori.com www.dmgmori.com
Product Line SLM Machines Powder Nozzle Machines Excellence Centre LASER DEPOSITION WELDING Laser Deposition Welding LASERTEC 3D and LASERTEC 3D hybrid WORKING PRINCIPLE Working direction Powder Laser beam Inert / Carrier gas Melt pool Applied material Building area Workpiece Using a coaxial nozzle, the metal powder is welded to and melted onto the base material in layers. The metal powder is thereby joined to the base material with a high-strength bond. Coaxial shielding gas protects against oxidation during the build-up process. After cooling, the metal layers can be machined mechanically. 1 MATERIALS Established materials: + Stainless steel (316L X2CrNiMo17-12-2) 24 + Tool steels (X35CrMoMn7-2-1, X20CrMoMn15-15-3) + High-speed steel (M2 S6-5-2) + Nickel-based alloys (625, 718) + Cobalt alloys (6, 21) + Copper alloys (CuSn10, CuAl10) 2 + MMC coating (WC in nickel-based matrix) + Density 99.8 % + Good mechanical properties + Option of manufacturing multi-material parts + Build-up of gradient materials 3 Size Unit 316L Ni 625 Yield point [R p0.2 ] Mpa 390 (±17) 538 (±13) Tensile strength [R m ] Mpa 563 (±22) 844 (±18) Elongation at break [A] % 36.6 (±3.2) 28.9 (±6.2) Notch impact strength [J] J 105 (±2) 52 (±1) 1: Ni-718 cuboid 2: Cross-section of a 316L cuboid 3: 316L cylinder
LASER DEPOSITION WELDING Applications PRODUCTION AEROSPACE Manifold ENERGY Blade AEROSPACE Turbine housing AEROSPACE Manifold ENERGY bucket wheel 25 ENGINEERING Nozzle MARINE Propeller FORMENBAU Injection mold REPAIR AEROSPACE Blisk ENERGY Impeller COATINGS TOOL MAKING VACUUM TECHNOLOGY Flange
Product Line SLM Machines Powder Nozzle Machines Excellence Centre LASER DEPOSITION WELDING Features HIGHLIGHTS + 5-sided additive process + Addition of additive features to existing parts + Coating and repair of existing parts + Large honeycomb structures for weight reduction + Combination of multiple materials in one part + Large cavities possible + Buildup of semi-finished products with inner contours + High-quality welding + Alternate buildup and machining Internal Feature Feasibility of channels within a solid part structure, e. g. cooling channels as well as similar complex internal structures as cooling elements and other similar cooling components for injection moulds 26 Multi Material Combination of two different materials in one part. Two individually selectable powder feeders allow the combination of various materials, even the building of Sandwich workpieces Graded Materials Systematic control of the transition from one material to another. This results in graded materials with a smooth transition between the different material properties. The toughness and hardness of the material can be regulated in the build-up process and optimally tailored to the specific requirements of the individual application. Build on parts This is based on an existing part (build-up by additive manufacturing or with an alternative production process). Flanging of an additional 3D contour onto the existing part 3D coating Deposition of partial or complete coatings for corrosion protection and wear resistance, 3D coating on 3D parts as a material coating or a repair
HIGHLIGHTS LASERTEC 65 3D hybrid AND LASERTEC 4300 3D hybrid Hybrid CAD / CAM module for additive and subtractive programming + One software package for the complete process (design, programming, simulation) + Unique SAUER LASERTEC buildup module fully integrated into CAD / CAM software + The part can be programmed in several steps, while flexibly switching between laser deposition welding and milling operations in only one programming set-up. 1: Customer CAD / CAM data; CAD model separation into additive and subtractive areas; slicing of the individual workpiece sections 2: Generation of the NC paths for the laser process and milling; output by post processor; definition of program order 3: 3D simulation for collision protection with consideration of the integrated laser head 4: Laser deposition welding and milling combined on the LASERTEC 65 3D hybrid / LASERTEC 4300 3D hybrid (flexible changeover possible) 5: Finished workpiece ready for quality inspection 27 LASERTEC 65 3D hybrid APPLICATION EXAMPLE Turbine casing, Aerospace: Inconel 718 / Bronze ø 194 80 mm Wall thickness: 6 mm 1 2 3 Building of the basic cylinder Building of the flange Machining of the flange 4 5 6 Laser deposition welding: 375 min. Milling: 35 min. Building of the outer connections Milling of the upper contour Milling of the connection surfaces
Product Line SLM Machines Powder Nozzle Machines Excellence Centre LASER DEPOSITION WELDING SIEMENS NX New Highlights TUBE ADDITIVE BUILD-UP + Build-up of curved geometries (filled, thick or thin wall) + Automatic generation of the tool path based on the component curve 28 + Increased flexibility in production + Application examples: Bend, bent pipes, blades MERGE + Simultaneous build-up of several operations + Prevention of collisions due to parallel setup of features + Combined setup of features with different parameters, materials or geometries + Application examples: Impeller, lightweight structures, multi-material components
black = F55 white = 316L GRADED MATERIALS + Automatic interpolation between two parameter sets along a defined course + Also usable for complex geometries + Fast programming possible with the NX material database + Application examples: Armouring, wear-intensive components 29 3D FREEFORM + Build-up on complex, existing surfaces + Coatings, thin walls and full components + Flexibility with regard to programming + Application examples: Drill head, tools, mould making
Product Line SLM Machines Powder Nozzle Machines Excellence Centre LASERTEC 65 3D 5-axis buildup of additive parts using powder nozzle With the new compact LASERTEC 65 3D, DMG MORI is expanding its product range for additive manufacturing with powder nozzles. Additive manufacturing can be carried out on the 5-axes simultaneous machine tool, while preperation and finishing operations are carried out on other machine tools. This means that both additive and milling capacities can be used to the optimum. The LASERTEC 65 3D also has a working space that is approx. 40 % larger than the hybrid version, combined with a footprint that is approx. 45 % smaller. DMG MORI offers the complete process chain, from NC programming in CAD / CAM to post-processing on DMG MORI machines. 30 HIGHLIGHTS + Laser deposition welding based on a CNC machine tool + 5-axis buildup of large additive 3D metal parts up to ø 650 mm, 560 mm in Z + Workpiece weight: 600 kg + Laser head integrated into the headstock + Possibility to change between various track widths (ø 1.2 3.6 mm) + Higher laser power of up to 4 kw + Complete hybrid CAD / CAM process chain (with interface for subtractive post-processing)
Your contact person Richard Kellett Product Manager Additive Manufacturing LASERTEC 65 3D Floor plan SAUER GmbH DECKEL MAHO-Str. 1 DE-87459 Pfronten Tel.: +49 8363 89 6516 Fax: +49 8363 89 2793 Mobile: +49 151 4225 7942 richard.kellett@dmgmori.com www.dmgmori.com 770 1,040 2,357 783 859 598 852 685 1,571 4,626 3,055 1,962 Technical data 31 LASERTEC 65 3D Working area / drives Travel in X / Y / Z mm 735 / 650 / 560 Work table / workpieces Clamping surface rigid table mm 800 650 Dimensions (NC swivel / rotary table) mm ø 650 Max. Workpiece dimensions mm ø 650 560 Max. Workpiece weight (NC swivel / rotary table) kg 600 Rotary axis (C-axis) degrees 360 Swivel range (A-axis) degrees 120 bis +120 Pmax under VDI / DGQ 3441 (C-axis / A-axis) Ws 7 / 9 Laser source Fibre laser diode (standard) Watt 2,500 Fibre laser diode (optional) Watt 3,000 / 4,000 Focal length (fixed) mm 300 Laser spot diameter 1 (standard) mm 3 Laser spot diameter 2 (optional) mm 1.2 3.6 Buildup rate (depending on material kg / h 1.0 Linear axes (X / Y / Z) Rapid traverse speed mm 40 / 40 / 40 Max. Acceleration X / Y / Z m / sec² 6 / 6 / 6 Pmax under VDI / DGQ 3441 mm 0.008 Machine data Width depth height (basic machine) mm 2,614 3,825 2,912 Machine weight kg 11,000
Product Line SLM Machines Powder Nozzle Machines Excellence Centre LASERTEC 65 3D hybrid: ADDITIVE MANUFACTURING IN FINISHED PART QUALITY Laser deposition welding with integrated milling The combination of laser deposition welding with a metal powder nozzle and milling on the LASERTEC 65 3D hybrid is an innovative additive machining method. It allows faster production of complex geometries and customised parts. The flexible changeover between laser and milling operations enables the direct machining of areas that can no longer be reached later on the finished part. DMG MORI is offering the complete process chain: NC programming in hybrid CAD/ CAM, technology parameters from a material database, machining, process monitoring and documentation. 32 HIGHLIGHTS + The flexibility of additive manufacturing combined with the precision of machining + Laser generation of the workpiece with intermediate milling + High buildup rates due to coaxial powder nozzle + Buildup of parts without support geometries, due to 5-axis application + Large work area for workpieces up to ø 500 400 mm height + Max. workpiece weight 600 kg + Reduced material usage
Unique technology integration PATENT PENDING Laser deposition welding with a powder nozzle Hybrid CAD / CAM module for laser and milling process + Intelligent combination of laser deposition welding and milling for highest surface quality and part precision + Reliable high-quality welding by combining laser deposition welding with the precision of a CNC machine tool + One universal solution for additive buildup and subtractive machining for design, programming and processing 33 PATENT PENDING Closed loop In-process regulation, analysis and control + Continuous measuring and monitoring of the buildup process + Automatic regulation of laser power ensures a completely closed loop in real time + Ensuring of a uniform welding process + Process monitoring for maximum process safety and homogeneous part quality Flexible integration of laser head via HSK interface + Automatic changing of the laser head via shuttle handling without manual intervention + Coaxial nozzle for uniform powder distribution + Independent of the laser buildup direction + Integrated safety gas monitoring + Optimum powder volume supply + Protected against dust, chips and coolant during milling Additive Manufacturing material database for users + Basic parameters for users and hybrid CAD / CAM for a wide variety of materials + Development of process parameters for surfaces, ridges and 3D parts + Customer-specific material developments in five Additive Manufacturing Technology Centres worldwide
Product Line SLM Machines Powder Nozzle Machines Excellence Centre LASERTEC 65 3D hybrid Floor plans Front view 3,279 3,078 2,877 2,752 2,372 1,734.5 2,000 0 4,663 34 Top view 1,050 3,218 1,560 5,037 401 activecooling Oil mist separator inside tool magazine 1,826 exhaust system 450 600 cooling unit 4,025 5,321 1,687 band filter unit 848 1,476 5,886 2,075 + Also: Gas package argon or central client supply
Your contact person Richard Kellett Product Manager Additive Manufacturing LASERTEC 65 3D hybrid Technical data SAUER GmbH DECKEL MAHO-Str. 1 DE-87459 Pfronten Tel.: +49 8363 89 6516 Fax: +49 8363 89 2793 Mobile: +49 151 4225 7942 richard.kellett@dmgmori.com www.dmgmori.com LASERTEC 65 3D hybrid Working area / drives Travel in X / Y / Z mm 735 / 650 / 560 Work table / workpieces Dimensions (NC swivel / rotary table) mm ø 650 Max. Workpiece dimensions (Additive Manufacturing) mm ø 500 400 Max. Workpiece weight (NC swivel / rotary table) kg 600 Rotary axis (C-axis) degrees 360 Swivel range (A-axis) degrees 120 bis +120 P max under VDI / DGQ 3441 (C-axis / A-axis) Ws 7 / 9 milling spindle Max. Speed (standard / optional) rpm 10,000 / 18,000 Output 40 % DC / 100 % DC (standard) kw 13 / 9 Torque Nm 83 / 57 Tool holder Type HSK-A63 Laser source Fibre laser diode (standard) Watt 2,500 Focal length (fixed) mm 200 Laser spot diameter 1 (standard) mm 3 Laser spot diameter 2 (optional) mm 1.6 Linear axes (X / Y / Z) Rapid traverse speed mm 40 / 40 / 40 Max. Acceleration X / Y / Z m / sec² 6 / 6 / 6 P max under VDI / DGQ 3441 mm 0.008 Tool change system Standard / optional tools Number 30 / 60 / 90 Machine data Width depth height (basic machine) mm 4,180 3,487 2,884 Machine weight kg 13,000 35 SAUER LASERTEC EXCELLENCE CENTRE IN PFRONTEN + > 25 years of experience in laser precision machining + > 700 LASERTEC machines installed (worldwide) + Application expertise: Training, customer support, complete turnkey solutions + Regular LASERTEC technology seminars
Product Line SLM Machines Powder Nozzle Machines Excellence Centre LASERTEC 4300 3D hybrid: ADDITIVE MANUFACTURING IN FINISHED PART QUALITY Laser deposition welding with integrated milling and turning The LASERTEC 4300 3D hybrid expands the range of hybrid machines with a milling / turning machine for the ideal manufacturing of rotative parts. The main and sub-spindles allow 6-sided machining of parts, including the welding of pipes through automated sub-spindle handling. 36 HIGHLIGHTS + Combined laser deposition welding and turning / milling operations on the LASERTEC 4300 3D hybrid + Large parts up to ø 660 mm, 660 mm in Z (axial) or ø 545 mm, 1,500 mm in Z (rotative) + Max. workpiece weight 1,700 kg + Top surface quality and precision due to the integrated 5-axis turning machine + Additive manufacturing of metals and reactive materials such as Ti-6Al-4V (optional) + Complete hybrid CAD / CAM process chain (additive and subtractive)
Unique technology integration + Laser deposition welding and 6-sided 5-axis simultaneous machining with an intelligent combination of turning and milling Laser head + Laser power of up to 10 kw + Integrated cooling Flexible changeover of different additive manufacturing heads + Revolver with up to five additive manufacturing laser heads + Automatic laser head changer 37 Titanium package + Safe additive manufacturing with titanium powder + Additional argon safety gas supply via specifically constructed nozzles + Certified non-flammable titanium powder (Ti-6Al-4V) + Safety cycle guarantees correct powder supply + Wet separator for filtering machine waste air + Additional cleaning kit + Safety package for machine operators Intelligent process monitoring and control + 2-colour pyrometer + Closed control loop: Automatic regulation of laser output for constant melt pool temperatures + Feedback from melt pool + Conversion of brightness into corresponding temperatures + Automatic adjustment of laser power to ensure a constant temperature is maintained in the melt pool Complete integration into CELOS + CELOS with SIEMENS 840D sl Operate including 21.5 ERGOline control system with multi-touchscreen + 3D apps and AM control + Ready for Industry 4.0
Product Line SLM Machines Powder Nozzle Machines Excellence Centre LASERTEC 4300 3D hybrid Deposition envelope for additive manufacturing B-Achse 90 B-Achse 0 18 38.5 ø 660* ø 545* ø 350 ø 200 ø 660 660* 375 265 38 210 1,300 * mm ADDITIVE AND SUBTRACTIVE MACHINING ON MAIN AND SUB SPINDLE + Complete 6-sided machining of parts + Buildup of parts on main and sub spindle with subsequent welding of built-up parts + Automated connection welding of parts and subsequent build-on features
Your contact person Nils Niemeyer Product Sales Manager LASERTEC 4300 3D hybrid Technical data DMG MORI USA 2400 Huntington Blvd. Hoffman Estates, IL 60192 Mobile: +1 (224) 633-8338 nniemeyer@dmgmori-usa.com www.us.dmgmori.com LASERTEC 4300 3D hybrid General Machine weight (standard) kg 31,720 Footprint mm 6,690 9,393 Tool spindle (Turret 1) Linear axes X / Y / Z mm ø 660 / +190 bis 210 / 1,500 Spindle angle (B-axis) 30 bis 210 Rapid traverse (tool spindle) m / min X: 50 Y: 30 Z: 50 Max. workpiece weight kg 1,700 Tool spindle motor (10 min. / cont.) kw 18.5 / 11 Max. spindle speed rpm 12,000 Tool spindle torque (10 % DC / cont.) Nm 120 / 44.5 Chuck Type Capto C6 [BT 40] [HSK-A63] [CAT40] Tools (optional) # 20 (60) (100) Max. tool weight kg 8 (10) Main spindle 1 + 2 Max. turning diameter mm ø 660 (tool spindle) > ø 350 (Turret 2) Rotary axis (C-axis) 360 Max. spindle speed / chuck (spindle 1 + 2) rpm 3,000 (10,000) / JIS A_2-8 Spindle motor power (30 min. / cont.) kw 30 / 25 Spindle motor torque (30 min. / cont.) Nm 1,302 / 1,038 Clamping diameter mm 300 Turret 2 Transverse axes X2 / Z2 mm 195 / 1,525 Rapid traverse (Turret 2) m / min A: 50 X2: 50 Z2: 50 No. of tools (Turret 2) # 10 Max. milling spindle speed (Turret 2) rpm 6,000 (optional) Turret 2 milling spindle motor power (5 min. / cont.) kw 5.5 / 3.7 Powder buildup Material Stainless steel / maraging steel / Inconel 625 / 718 / stellite / copper / titanium Buildup rate (depending on material) kg / h 0.8 1 (at 3 kw) Laser Fibre diode laser, coupled (optional) Watt 3,000 (6,000) (10,000) Focal length (fixed) mm 300 @ laser spot 1 (158 @ laser spot 2) Laser spot 1 mm ø 4 / 4 10 (rectangle) Laser spot 2 mm ø 2 AM tool changing Automatic Additive Manufacturing tool changer and revolver Laser beam / powder nozzle rotation Tangential guide 39 Floor plans available upon request.
DMGMORI.COM DMG MORI GLOBAL No. 1 for ADDITIVE MANUFACTURING in metal With our five Additive Manufacturing Technology Centres in Bielefeld, Pfronten, Shanghai, Tokyo and Chicago we can look after our customers locally in the most important focus markets. There we can develop local technology and material needs, as well as handling concrete part requests and training enquiries. AMEC Pfronten, Germany AMEC Shanghai, China AMERICA AMEC Tokyo, Japan AMEC Chicago, USA EUROPE ASIA Chicago Shanghai Japan Germany Bielefeld Tokyo Pfronten Subject to technical changes. The machines depicted here may include some options, equipment and CNC alternatives. AMEC Bielefeld, Germany WORLDWIDE SERVICE P20180287_0618_EN 157 sales and service locations, 14 production factories as well as 5 Additive Manufacturing Excellence Centres worldwide.