DMG MORI to present hybrid powder-based DED and PBF-LB at Formnext
DMG MORI, headquartered in Tokyo, Japan, will be demonstrating how the Additive Manufacturing of metal components can be further optimised at the upcoming Formnext, taking place November 18 to 21, 2025, in Frankfurt, Germany. The company offers both Directed Energy Deposition (DED) and Laser Beam Powder Bed Fusion (PBF-LB) Additive Manufacturing machines, as well as a range of ancillary equipment.
LASERTEC DED
The LASERTEC DED hybrid 6-in-1 machines employ milling, turning and grinding, as well as preheating, powder-based DED Additive Manufacturing and a 3D scanner. The advantages include the ability to switch between subtractive and additive technologies, allowing for the development of complex geometries and multi-material applications that can be equipped with tailor-made properties, such as enhanced wear or corrosion protection and increased resistance to chemicals. In addition, tool inserts, for example, can be repaired cost-effectively.
As the latest part of this process chain, preheating minimises stress and prevents cracks between the base material and the weld material, which improves mechanical properties. A tool-changer-compatible 3D laser scanner enables non-contact and precise quality control through false colour imaging. The optional use of blue lasers expands the material spectrum to include highly reflective metals, such as copper, and allows for graded material transitions in highly functional components.
At the end of the process chain, precise finishing is performed on the same machine. All steps, from preheating to scanning and material application to machining, can be flexibly combined and repeated. This transforms a complex, multi-stage process into a consistent, highly automated workflow, demonstrating the practical suitability of hybrid manufacturing for series production.
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LASERTEC 30 SLM 3. Generation
The LASERTEC 30 SLM 3. Generation is a PBF-LB Additive Manufacturing machine with a number of innovative features. These include an interchangeable ‘construction container’, which eliminates one of the biggest bottlenecks in metal AM: the long cooling times after construction jobs. Finished containers can be removed immediately after completion and replaced by prepared containers, meaning the machine remains productive almost without interruption. Set-up times are also significantly reduced, as the preparation of the building boards will be carried out externally in the future.
This not only eliminates the need for repeated flooding of the chamber with inert gas but also significantly reduces the consumption of the shielding gas. An integrated lid system also enhances safety and maintains a protective atmosphere between two jobs, enabling powder management and material handling under inert gas conditions.
With an expanded build space of 325 × 325 × 400 mm, larger or more components can be manufactured in parallel, making the machine attractive for series production.
DMG MORI will also present the new rePLUG FLEX, a simplified version of the proven rePLUG powder module. This variant does not require a closed powder circuit within the machine. On the other hand, the material change can be carried out without an additional powder module, an economical solution, especially for materials that are only used on a smaller scale.
ADDITIVE INTELLIGENCE
The consulting unit ADDITIVE INTELLIGENCE is designed to make it easier to get started with AM. The in-house experts 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 comprehensive package which the company states offers a competitive advantage. The production of customer parts can also be implemented in this division.
