Mazak continues to fortify its industry leadership in HYBRID Multi-Tasking machine technology with the introduction of its new INTEGREX i-200S AM (Additive Manufacturing). With an innovative multi-laser deposition system, the machine provides both additive and subtractive capabilities. Shops can not only turn, mill and drill, but also build part features and perform laser marking all on the same machine and in single setups for DONE IN ONE® production.
The INTEGREX i-200S AM excels in challenging applications, such as aerospace components, metal cladding for chemical plant valves and the repair of dies and turbine blades. Ideal for the production of mid-size complex components, the machine makes it possible to quickly and easily grow part features. This capability significantly slashes production time and conserves large amounts of expensive raw materials typically machined away when parts are completely produced using only subtractive operations.
In addition to its two turning spindles and milling turret, the INTEGREX i-200S AM features dual laser cladding heads/additive manufacturing nozzles that provide options for both high and fine rates of metal deposition. Essentially, the two cladding heads complement each other much like roughing and finishing tools work together in common chip making operations. The cladding heads reside in the tool magazine with the machine’s automatic tool changer that loads/unloads them into/from the milling turret as needed.
During operation, the INTEGREX i-200S AM uses fiber laser heat to melt the chosen metal powder that will be used to the grow near-net-shape 3D forms. The cladding heads apply the molten material layer by layer, each of which solidifies as the desired part surface or features grows. Once the part features are grown to near net shapes, the INTEGREX i-200S AM then applies one or more of its advanced subtractive operations, including full 5-axis milling, turning, hobbing and contouring, to process the part complete.