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GLOBAL ONE – Integration. Innovation. Quality.

08.11.2016 - LASERTEC 65 3D

LASERTEC 65 3D – Additive Manufacturing in milling quality

Welcome to the future

The unique technology combination of laser deposition welding by means of powder nozzle and milling on the LASERTEC 65 3D is an innovative, generative manufacturing process which enables complex geometries and individualised components to be produced faster. In particular, large components up to 500 mm diameter can be manufactured quickly and efficiently with this hybrid solution. Flexible switching between laser machining and milling also enables component segments which are no longer accessible on the finished part to be machined directly.

This method uses a deposition process by means of a powder nozzle, which is up to 10 times faster than generation in a powder bed. Troublesome supporting geometries are unnecessary thanks to 5-axis deposition. DMG MORI provides the complete process chain, starting with NC programming in hybrid CAD/CAM and technology parameters from a material database to the actual machining of the component, process monitoring and documentation.This innovative process from SAUER GmbH is increasingly finding its way into industrial manufacturing. Even today, components such as a cutter for processing sheet metal in automobile production, for example, can be produced quickly, cost-effectively and in outstanding quality on the LASERTEC 65 3D. In comparison, conventional casting technology is very time-intensive. Furthermore, changes to the component geometry during the process are difficult to accommodate.

In order to build up the cutter, 3D CAD data are transferred to Siemens NX and all additive and conventional machining strategies are programmed. A 3D simulation is also displayed to check for collisions taken into account the integral laser head. The complete machining program is then transmitted to the machine and the manufacturing process can be started immediately.

The cutter is built up on a base plate using laser deposition welding and then milled. In this case, two different materials are built up in one process. One for the main volume and a second, hard material for the cutting edge (for example HSS 63 HRC). The cutting edge is then processed conventionally or machined using the optional ULTRASONIC technology. This innovative method reduces the manufacturing process from 60 to 3 days.

A further advantage is that the same tools can be maintained on the same machine without long set-up times and the programmed component built up several times without major effort.

As a result, the LASERTEC 65 3D offers a unique selling point in additive manufacturing.
The highlights at a glance:

  • Flexibility of generative manufacturing combined with the precision of chip removal
  • Workpiece can be built up using a laser with intermediate milling
  • High build-up rates with coaxial powder nozzle
  • Large work area for workpieces up to Ø 500 x 400 mm high
  • Reduced material usage

Do you have any questions? We have the answers! Our Additive Manufacturing technology centres in Pfronten, Chicago, Tokyo and Singapore enable us to support our customers locally in the main focus markets in the fields of technology and material development, the handling of specific component questions and training enquiries. We look forward to hearing from you.


Additive Manufacturing of a cutting tool for sheet metals in the automotive industry on a LASERTEC 65 3D


LASERTEC 65 3D: Generative manufacturing in finished-part quality


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