Hybrid Multitasking Machine Combines Subtractive, Additive Capabilities

Mazak’s Integrex i-400AM hybrid multitasking machine combines additive technology with machining, reducing part cycle times while providing high-efficiency done-in-one processing.

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Mazak’s Integrex i-400AM hybrid multitasking machine combines additive technology with machining, reducing part cycle times while providing high-efficiency done-in-one processing. The technology is said to be especially well-suited for small lot production in very difficult-to-cut materials such as those used in the aerospace, energy and medical industries.

The machine’s additive capability enables manufacturers to generate/clad near-net-shape component features and then quickly complete them with high-precision finish machining operations, the company says. Parts also can be laser-marked, if needed.

In operation, the Integrex i-400AM melts metal powder using fiber laser heat. Cladding heads apply the molten material, layer by layer, each of which solidifies as the desired shape grows. Plus, the system can join different types of metals to one another, which is beneficial in the efficient repair of existing worn or damaged components.

Cladding heads store in the machine’s tool magazine, and the automatic toolchanger loads them into the machine’s milling turret. Users can select either a high-speed or high-accuracy cladding head, based on the intended process and the particular metal powder to be used.

On the multitasking machine side, the Integrex i-400AM provides full five-axis capability to process prismatic parts from solid billets or castings (chucked or bar-fed), round parts, highly contoured parts, and now those with features built using additive technology. The machine provides -30/+210-degree B-axis movement in its milling spindle, full C-axis contouring with its turning spindle and an NC tailstock that is fully programmable.