DMG MORI plans to demonstrate at Formnext (18–21 November 2025, Frankfurt) how additive processes can be embedded into hybrid and production-like workflows. The focus is on two lines: the LASERTEC DED hybrid for laser deposition welding with machining finishing, and the third-generation LASERTEC 30 SLM powder bed system. The manufacturer points to shortened throughput times, higher process stability, and traceable material flows that are relevant for regulated industries.
The DED hybrid machines combine milling, turning, grinding, preheating, powder-based material deposition, and integrated 3D scanning in a single setup. Preheating reduces residual stresses and mitigates cracking between base and weld metal. A toolchanger-capable laser scanner captures geometries without contact and highlights deviations using false-color mapping. Optionally available blue laser sources expand the material spectrum to highly reflective metals such as copper and support graded material transitions. Switching between additive and subtractive steps enables repair of tool inserts as well as the build-up of functional zones with targeted wear or corrosion protection before finishing on the same machine.
On the third-generation LASERTEC 30 SLM, a swappable build container addresses downtime caused by cooling phases. Finished containers are removed and prepared ones inserted; setup operations move outside the machine. This reduces inert-gas purging and consumption; a lid system maintains the protective atmosphere between jobs. A cast frame and a floating-mounted process chamber are designed to damp thermal influences, while active Z-axis compensation stabilizes layer height. Up to four overlapping lasers process an enlarged build volume of 325 × 325 × 400 mm. For rarely used materials, DMG MORI offers the rePLUG FLEX, which dispenses with a closed powder circuit and simplifies material changes. Via CELOS X with easyAM, camera inspection of the powder bed, heat-map analysis, and an “Anomaly Score,” layer data are visualized and correlated with image data.
In addition, the ADDITIVE INTELLIGENCE unit provides consulting from part selection through to series transfer; according to the company, more than 3,000 components for its own machines are produced there each year. The trade fair presence is intended to show how additive and machining steps can be linked into robust series processes.
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