Additive manufacturing and 5-axis machining on one platform

The Integrex i-400 AM integrates Direct Energy Deposition additive manufacturing technology into a 5-axis Multi-Tasking machine to offer machine users hybrid technology, combining the benefits of additive and subtractive manufacturing into one platform.

The Integrex i-400 AM makes use of a built-in 1kW fiber laser to melt metallic powder, which is then applied layer by layer via interchangeable cladding heads. These heads are stored in the machine’s standard 36-tool magazine and provide the ability to automatically change between additive and subtractive tooling, optimising process cycle time. Once the additive manufacturing process is complete, the machine’s Multi-Tasking capability finishes the component.

The latest generation of the Integrex i-400 AM incorporates a full A and C axis NC Table providing the capability to both machine or clad simultaneously in full 5-axis, further enhancing the application geometry that can be generated.

The Integrex i-400 AM technology can be used to clad a range of material types, including stainless steel, nickel alloys and copper. This capability to cover a variety of materials makes the machine suitable for a range of applications, from repairing existing worn or damaged components, to the addition of critical features or the complete generation of new parts.

The Integrex i-400 AM will be exhibited with two new high-performance heads, a high-speed cladding head for high rate material deposition delivering a bead size of 3 x 1mm and a fine cladding head for more intricate feature generation with a bead size of 1 x 0.5mm, providing robust process flexibility to meet a range of application requirements.

The Integrex i-400 AM, which is now available with SmoothX control, has full 5-axis machining capability to efficiently process prismatic, round and highly contoured work pieces, as well as those near net features which have been created using the integrated additive technology. Finished parts can also be laser marked if necessary using the same head technology.

The Integrex i-400 AM has 50m/min rapid traverse rates, a main spindle capable of delivering 3,300rpm/30kW and a 12,000rpm/22kW milling spindle.

The Integrex i-400 AM incorporates Mazak’s latest generation of CNC, SmoothX, which has been ergonomically designed with the operator in mind. The operating panel boasts a 19in touch screen, and can be tilted and rotated to suit the posture of the operator.

The new ‘Quick Mazatrol’ interface also reduces the number of keystrokes to write a conversational program by 38 per cent compared to its predecessor. Control of both subtractive machining and additive cladding is fully integrated into the control providing a single ergonomically designed interface from which the operator can easily program and oversee all applications.