Mazak says visitors to its latest Open House event were impressed by a demonstration of one of its Integrex i-400AM
five-axis hybrid multi-tasking machine tools, which was programmed using Edgecam software to produce a ‘hybrid gear’ by depositing — and then machining — different materials, tooth by tooth.

Supporting the Directed Energy Deposition method, Edgecam now offers a manufacturing cycle that accurately guides a laser as it deposits material to form a shape.

After the deposition process is complete, the shape is machined using Edgecam’s milling cycles to create the final component (shapes can be built using almost any milling cycle).

Woody Darlington, Mazak’s additive-manufacturing technical specialist (www.mazakeu.com), said Open House visitors (some 500) appreciated how the seamless switch between depositing material and machining provides a solution that not only saves material and costs but also reduces waste and inventory time.

“This process enables parts to be repaired and remanufactured; it can also produce hybrid material components with enhanced performance and longevity.

“Using Edgecam on this Mazak machine tool means five-axis tool-paths can be produced very quickly, saving considerable time for manufacturers.”

The demonstrations showed three different ways of producing a gear tooth, using stainless steel, Inconel and a tungsten carbide/nickel matrix.

Edgecam’s Simon Beamish (www.edgecam.com) said: “The additive lace cycle means that Edgecam accurately guides the laser, depositing material to form the gear-tooth shape, after which Edgecam’s milling cycles creates tool-paths to produce the final machined tooth.

"Working closely with Mazak gave us the opportunity to fully understand the requirements of their specialist machine, not only from the tool-path build process but also the Additive.EIA code output.”