As one of many world’s main CNC machine instrument producers, DMG MORI is strengthening its place throughout each standard and additive manufacturing (AM). At Formnext 2025 (November 18–21, Frankfurt), the corporate introduced new developments that push hybrid and powder mattress applied sciences nearer to true industrial-scale manufacturing.
With its LASERTEC DED hybrid and LASERTEC SLM methods, DMG MORI has demonstrated how AM can transfer past prototyping and turn into totally embedded inside environment friendly, automated workflows.
“Hybrid manufacturing is not a distinct segment—it’s turning into the brand new commonplace for environment friendly, versatile manufacturing,” mentioned Patrick Diederich, Managing Director DMG MORI Ultrasonic Lasertec GmbH. “By merging additive and subtractive processes into one seamless workflow, we’re redefining what industrial manufacturing can obtain,” mentioned Diederich.
Hybrid Manufacturing: Six Processes, One Machine
On the core of this method are the LASERTEC DED hybrid machines, combining six manufacturing steps—milling, turning, grinding, preheating, laser deposition welding, and 3D scanning—inside a single setup. This 6-in-1 configuration allows end-to-end half manufacturing in a single clamping operation, dramatically chopping lead occasions and eliminating the necessity for exterior processes, transport, or rework.
The flexibility to alternate between additive and subtractive modes lets customers create complicated geometries and multi-material components with enhanced put on resistance, corrosion safety, or chemical stability. Parts akin to instrument inserts will also be repaired relatively than changed, extending service life and lowering downtime.
New course of improvements, together with preheating, scale back inside stress and stop cracking between base and deposited supplies, enhancing mechanical efficiency. A tool-changer built-in 3D laser scanner ensures exact, non-contact high quality inspection with false-color imaging, whereas blue laser know-how expands capabilities to extremely reflective metals like copper and allows graded materials transitions for superior, high-performance elements.
“These new capabilities rework a fancy, multi-step course of right into a streamlined, automated workflow—demonstrating that hybrid manufacturing is prepared for collection manufacturing. It exhibits how additive manufacturing can complement, not compete with, conventional machining by combining the perfect of each worlds to spice up productiveness and half efficiency,” mentioned Diederich.
Powder Mattress Effectivity: LASERTEC 30 SLM third Era
Within the powder mattress fusion house, DMG MORI’s LASERTEC 30 SLM third Era addresses one in all metallic AM’s main challenges: downtime between builds. Its new interchangeable construct container system permits accomplished jobs to be swapped out shortly—no cooling delays—protecting manufacturing operating nearly constantly. Setup time is additional decreased via exterior build-plate preparation, minimizing inert fuel consumption and avoiding repeated chamber purging. A sealed lid additionally allows protected powder dealing with.
A bolstered course of chamber with lively Z-axis compensation ensures layer stability and positional accuracy, and as much as 4 overlapping lasers allow quicker, extra constant outcomes. The expanded 325 × 325 × 400 mm construct quantity allows bigger elements or a number of components in parallel, making the system ideally suited for serial manufacturing.
The machine is operated intuitively through CELOS X with easyAM, combining good controls with built-in course of monitoring for constant half high quality. Its built-in digital camera system constantly displays every layer, detecting and analyzing floor irregularities in actual time.
DMG MORI demonstrated the know-how at Formnext 2025 by printing a robotic head from its Robo2Go Open system, and likewise introduced rePLUG FLEX, an optimized powder module developed for economical materials modifications in small collection or particular purposes.
“At DMG MORI, we see AM not as an remoted know-how, however as an integral a part of a wiser, extra related manufacturing ecosystem. By combining course of chains, digital options, and professional steerage, we empower producers to maneuver from idea to collection manufacturing with confidence. That is how we flip innovation into measurable worth,” mentioned Diederich.
Wish to assist form the way forward for AM? Be a part of the Skilled Committee for our 2025 3DPI Awards, launching later this summer season.
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Featured picture exhibits LASERTEC SLM methods. Picture through DMG MORI.