DMG Mori, headquartered in Nagoya City, Japan, has announced that it will showcase its LASERTEC 30 Dual Laser Beam Powder Bed Fusion (PBF-LB) linked to a DMP 35 vertical machining centre at Formnext 2022. The company will also present a 5-axis LASERTEC 65 Directed Energy Deposition (DED) hybrid machine which combines Additive Manufacturing with milling and drilling. This machine incorporates a blue laser with a 450 nm wavelength which enables the more efficient processing of reflective materials.
Due to its high thermal conductivity, copper gives injection moulds and forming tools improved cooling properties, while in the aerospace sector it is used in nickel-base superalloys to form heat shields.
Many multi-material components, such as a die casting mould with a bronze core, can only be realised by Additive Manufacturing explains DMG Mori. A LASERTEC 65 DED is able to build up the core, mill functional cooling channels in it and then deposit a layer of hot-work tool steel in the same process, enabling good heat dissipation during casting. Mould repair is another application for machines in the LASERTEC DED hybrid series. Material is first applied to the damaged area and then milled on the same platform to achieve a repair quality equivalent to the original surface.
In the case of the twin-laser LASERTEC 30 DUAL, an additively manufactured workpiece can be transferred to the 5-axis DMP 35 machining centre, where it is milled to achieve the required surface quality. This machine is also able to finish a previously milled component in the powder bed without the need for support structures. A zero-point clamping system is said to provide an accurate interface for transferring the component between the powder bed and CNC machine, while DMG MORI’s app-based CELOS control enables a continuous digital workflow.
DMG Mori will also feature its AM Assistant – a combination of hardware and software that is intended to ensure a stable process in its DED machines. It continuously monitors and controls important process parameters such as laser power, powder mass flow, shielding gas, melt pool size and temperature, and clearance between nozzle and component.