LASERTEC 125 DED hybrid
Directed energy deposition combined with 5-axis milling, for building and repairing of high-value metal parts
Max. X-axis stroke
53 in.
1,335 mm
Max. Y-axis stroke
49 in.
1,250 mm
Max. Z-axis stroke
35 in.
900 mm
Max. laser power
3,000 W
3,000 W
Max. workpiece weight
4,409 lbs.
2,000 kg
Highlights
LASERTEC 125 DED hybrid - Additive Manufacturing
Proven monoBLOCK design for the best machine performance
- Fiber-guided diode laser with 3,000 W power and 600 µm fiber diameter
- Powerful motor spindles up to a maximum of 20,000 rpm
- NC swivel rotary table with swivel range A-axis: + 120 ° / -120, C-axis 360 ° endless, for up to 2,000 kg component weight
- Large door opening of 1,900 mm and unique access to the work area with minimal space requirements
- Comprehensive cooling measures, powerful cooling unit and multi-sensor compensation as standard
High flexibility of manufacturing processes by combining welding and milling on one machine for additive manufacture and repair
- The laser deposition head is handled by a fully automatic shuttle without manual intervention
- 5 axis material deposition by coaxial nozzle for homogeneous powder distribution, independent of direction of laser deposition welding
- Full 5-axis milling capability based on the monoBLOCK machine
AM Assistant for the best process reliability and comprehensive traceability
- Integrated thermal imaging camera for observation of the whole working area, adapive process control and constant monitoring of the working distance
- Powder feed rate sensor as well as automatic powder calibration.
- AM Evaluator for visualisation of the relevant process data (e. g. meltpool size, powder mass flow) as a digital 3D-model as well as in the chronological sequence
Siemens NX: Complete Hybrid CAD / CAM – Module for additive and subtractive programming
- One software package for the complete process chain (design, additive process, substractive machining, finishing)
- Exclusive LASERTEC build-up strategies - fully integrated in the CAD / CAM software incl. 3D-simulation of machine movements for collision prevention
- Change between additive and machining programming strategies all within one programming environment.
Using Multi-Materials and Gradient Materials for Improved Part Performance
- Selectively adding materials with more than 60 Rockwell to avoid heat treatment processes
- Improving cooling performance by using bronze material in the mould core
- Better materials and improved reliability in the repair process for increased service life
- Improved performance of exisitng tool designs by adding wear resistant coating
- Material gradients between hard and soft, magnetic and non-magnetic, etc.
Application Examples
Control & Software
AM Evaluator
- Visualization of relevant process data (for example, melt pool size, powder mass flow) as a digital 3D model and over time
- Detailed analysis of process data
- Direct comparison of processes for quality assurance
- Creation of part reports
Highlights
Customer Benefits
- Simplification of process development
- Support in quality control
- Enables individual analysis and work up of process-relevant data
- Easy retrofitting of the software within the AM-Analyzer product package (Existing software can still be used)
Left: Detailed analysis of process data using 3D digital models / Right: Overview of process-relevant data and comparison of different data sets
gearQUALITY
- Non-contact measurement with the laser scanner
- Measurement and evaluation of gears according to common standards analog to coordinate measuring machines
- Fast measurement with max. 70,000 points / sec. or up to 200,000 points / sec. depending on the laser source
Highlights
Customer Benefits
- Technology and measurement system integration eliminate unnecessary handling of components
- High flexibility in gear measurement and reduction of reaction times during process start-up
- Measurement of gear teeth and scanning of free-form surfaces possible
Left : Simulation of the generated measurement program / Right : Evaluation mask with color-coded result display
VCS Complete
- Geometric fingerprint of the machine Volumetric calibration at the touch of a button
- Detection and compensation of geometrical, positioning and angular errors of all axes
- Easy handling and implementation by the customer directly at the machine
Highlights
Customer Benefits
- Regular compensation of the machine geometry over the entire life cycle of the machine
- Dialogue-led operation for easy and fast handling
- Data recording for further analysis
Possible accuracy deviation without VCS-Complete.
Tilted Measuring Cycle
- Measuring with tilted tool axis
- Dialog-guided programming of the measuring cycles
- Positioning of the measuring points with rotary axis
Highlights
Customer Benefits
- Increase in component accuracy
- Reduction of set-up time
- Collision-free measuring thanks to tilted tool axis possible
- Further processing of the measurement results
Left : 1. circumferential measurement, 2. alignment surface, 3. alignment hole / Right : Dialog-guided programming
L-Measuring probe packet
- Measurement of webs and grooves on components
- Measurement of diameter in difficult to access places
- Available with manual and retractable Calibration unit Package content
- L-Measuring probe according to Customer-specific design
Highlights
Customer Benefits
- Flexible application possibilities
- In process measurement
Left : Semi-automatic Measurement solution. / Right : Automatic measurement solution.
angularTOOL
- Highest flexibility in the machining of structural components due to variable alignment of the angle head
- Automatic CAD / CAM programming
- Automatic calculation of the TCP and combination with existing control functions
Highlights
Customer Benefits
- Machining of inaccessible positions on the workpiece.
- Savings in non-productive time due to fewer tool changes
- High cost savings due to the use of fewer tools
Left : Tool driven by KSS during drilling operation / Right : Parameter mask for variable angle setting
Maintenance Package i4.0
- Automatic recognition of tool pull-in force for consistently high process stability.
- Predefined cycle for automatic lubrication, every 75h or after 20,000 tool changes.
- Detection of leakage and measuring of usage of pneumatics system.
Highlights
Customer Benefits
- Efficient and timesaving lubrication without operator intervention
- High transparency by displaying the lubrication cycles and the current pull-in force.
- Data recording in combination with the optionally available Condition Analyzer for additional analyzes of air consumption and changes of the pull-in force
Detection of leakage and measuring of usage of pneumatics system.
Simple query of the monitoring parameters and the current pull-in force.
TCC – Tool Control Center
- Chip detection on plan pad and tool cone
- Monitoring of pull-in force
- Cutting edge control in process by symmetry monitoring of the bending moment per cutting edge
- Visualization of the bending moment over time via Graph
Highlights
Customer Benefits
- Tool and workpiece protection
- Optimized tool process
- Monitoring of the radial and axial spindle load depending on the actual pull-in force
Left: NEW; Middle: Wear; Right: Cutting edge break
Interpolation turning 2.0 – turning recessing cycle
- With interpolation turning, the tool cutter follows a circular movement, where the cutter is always oriented towards the center Of the circle.
- Possible for external and internal machining
- Synchronization and tool path controlled by the cycle
- NEW: in version 2.0 complex turning contours are possible (currently only available on the DMU 50, other machine types will follow)
Highlights
Customer benefits
- Easy manufacturing of sealing surfaces where milling operation might not be possible.
- Complete component processing in one clamping possible
- Reduced investment costs for tools
MPC 2.0 – Machine Protection Control
- Vibration monitoring in the process
- Rapid shutdown in case of a crash
- Manual retraction even in swiveled machining plane
- NEW: Torque monitoring
- New: Recommended with Protection Package for CTX TC machines
Highlights
Customer Benefits
MPC Graph: current and learned process values. / MPC Diagnostics: stock condition, number of impact and crash.
- Avoiding tool breakage
- Increase in machine availability
- Damage reduction
Efficient Production Package
- Solutions for a safe process and for the efficient use of important machining steps
- Applications: cone cleaning, tool data monitoring, safe withdrawal movement, tapping, deep hole drilling, external thread and spigot milling, internal thread and circular milling, reverse countersink cycle
- 12 stored machining strategies for stock removal, deep hole drilling, Pocket milling machines*
Highlights
Customer Benefits
- Runtime optimization according to individual application
- Safe retraction after program break
- Tool data monitoring
Left : Input mask for universal cycle pocket milling. / Right : Input mask for tapping cycle
Multitool
- Efficient use of multi-tip turning tools with more than one cutting edge on turn & mill
- Several "sister tools" on one main tool holder
Highlights
Customer Benefits
- Reduction of tool change times
- Saves tool magazine space
DMG MORI gearMILL
- Productive complete processing
- Cost-effective gear cutting on standard machine with standard tools
- Flexible for different gear geometries
- Quality inspection in the process
Highlights
Customer Benefits
- Program creation based on blank drawings and gear data
- Optimization of workpiece orientation e.g. after heat treatment
- Interface for coordinate measuring device (Klingenberg, Leitz, Zeiss)
Left : Input of the gear parameters for the geometry calculation of a spur gear. / Right : Grafische Betrachtung des Abwälzverfahrens.
Excentric turning and milling
- Superposition of the turning movement by additional X- and Y-traverses
- Applicable for turning and milling
Highlights
Customer Benefits
- Eccentric geometries easy to manufacture
- Exact axis coupling and synchronization in the background
Left : Enter the parameters for the position of the external workpiece area. / Right : Graphical representation of the position within the workpiece.
3D quickSET
Turning
- Measurement and correction of the position of turning and Pivot axes (C4, C3, B)
- Sag compensation possible
- Can be used in combination with standard probes from customers (recommended Renishaw, Blum)
Milling
- Toolkit for checking and correcting the kinematic accuracy of 4- and 5-axis machine configuration
- All head variations and table axes
Highlights
Turning Customer Benefits
- Reliable re-calibration of the machine before a highly precise processing
- Continuous documentation of machine accuracy
- No rejected parts due to unknown Geometric-deviations
Dialogue-guided measurement of the B- and C-axis.
Milling Customer Benefits
- Periodic recalibration of the machine with comprehensive documentation
- Highest kinematic accuracy in self-regulation
Define kinematics head
Application Tuning Cycle
- Process-oriented adjustment of the feed rate n relation to the table loading
- Minimization of machining time with maximization of the component quality
- NEW: Now also available for CTX TC. Ideal machining result with the highest machine dynamics*
*without consideration of feed weight
Highlights
Customer Benefits
- User friendly setting of the machine dynamics with included DMG MORI knowhow
- Time saving in roughing
- High surface finish during finishing
Left : ATC 2.0 – Milling: Consideration of table loading. / Right : ATC – Turning: for CTX TC for easy adjustment of the machine dynamics.
Service & Training
Downloads & Technical Data
Technology Data
Max. laser power
3,000 W
3,000 W
Workpiece
Max. workpiece weight
4,409 lbs.
2,000 kg
Work Area
Max. X-axis stroke
53 in.
1,335 mm
Max. Y-axis stroke
49 in.
1,250 mm
Max. Z-axis stroke
35 in.
900 mm