MACH 2016Being demonstrated at MACH by Coventry-based DMG Mori UK (www.dmgmori.com) was the Lasertec 65 3D, a machine that has integrated additive manufacturing with lasers into a fully fledged five-axis machining centre, thus allowing the additive manufacturing of full components to finished-part quality and with maximum precision — and steep contours can be produced without the need for supporting structures.

Moreover, the combination of additive manufacturing with material removal on one machine allows entirely new applications and geometries to be developed, while the flexible switching between laser and milling operations allows for the direct machining of features that could not be accessed on the finished part.

The Lasertec 65 3D uses laser deposition welding for the additive process, whereby metal powder is welded to the basic material; a co-axial shielding gas protects against oxidation during the build-up process, and the metal layers can be machined conventionally after cooling.

Furthermore, compared with powder-bed additive manufacturing, powder feed is up to 10-times faster; and depending on the laser and nozzle geometry, wall thicknesses from 0.1 to 5mm are possible. Workpieces up to 500mm in diameter, 350mm high and weighing a maximum of 600kg can be produced.