DMG MORI LASERTEC 65 DED Hybrid 2nd Generation Advances Multi-Process Additive Manufacturing!

DMG MORI has introduced the LASERTEC 65 DED hybrid 2nd Generation, a next-generation hybrid manufacturing platform that integrates laser deposition welding with five-axis simultaneous milling in a single setup. The system is designed to expand multi-process manufacturing capabilities by combining additive and subtractive operations within one machine environment.

The LASERTEC 65 DED hybrid brings together six processes in a single workspace: milling, turning, grinding, preheating, additive manufacturing using a powder nozzle and 3D scanning. This integration allows manufacturers to complete complex part production without removing the workpiece from the machine, improving accuracy while reducing setup times and handling steps.

A newly developed MultiJet nozzle enables five-axis material deposition with uniform powder distribution. According to the company, this enhancement increases build-up rates by 35 percent while reducing part costs by 47 percent. The expanded working area accommodates components measuring up to 840 mm by 350 mm or 680 mm by 400 mm, supporting workpieces up to 170 percent larger than the previous generation. The increased build volume also contributes to a reduction in volume-related costs by more than 70 percent.

Material versatility has been expanded through the availability of both infrared and blue laser technology. This combination enables efficient processing of highly reflective materials such as copper and supports graded material transitions as well as multi-material components. Manufacturers can tailor component properties to specific applications, achieving improved thermal performance, selective hardness exceeding 60 HRC and extended tool life without requiring additional heat treatment.

Process stability and traceability are reinforced through integrated monitoring systems equipped with cameras and sensors. These systems monitor parameters such as temperature, powder mass flow, melt pool energy and working distance, enabling closed-loop control of critical variables. All process data are visualized and documented in a three-dimensional, time-based digital format, supporting quality assurance and compliance requirements.

The redesigned powder management system emphasizes safe and efficient handling. It includes sealed argon containers, automatic extraction of fine particles and optional pressure and level monitoring. The machine’s monoBLOCK construction provides positioning accuracy of 4 microns along with improved volumetric accuracy. Wide access doors enhance ergonomic operation and simplify integration into automated production environments.

Operation and programming are managed through the CELOS X control platform in combination with Siemens SINUMERIK ONE and proprietary technology cycles. With the LASERTEC 65 DED hybrid 2nd Generation, DMG MORI continues to advance hybrid manufacturing by combining additive and subtractive processes into a unified, high-precision production system designed for complex, high-value components.