Tool and mold making, aerospace, energy, and general mechanical engineering increasingly require manufacturing systems that combine geometric freedom with high precision and repeatability. In these sectors, additive manufacturing is no longer limited to prototyping but is being integrated into serial production, repair, and functional surface enhancement. Hybrid machine tools that merge additive and subtractive processes in a single setup are therefore becoming a key enabler for industrial-scale adoption.
DMG MORI has developed the second generation of its hybrid manufacturing concept to address these requirements. The latest system integrates laser deposition welding with simultaneous multi-axis machining, extending the scope of additive manufacturing toward fully integrated complete machining.
Six integrated processes in a single workspace
The hybrid platform combines six manufacturing processes within one machine envelope: milling, turning, and grinding, alongside laser-based additive manufacturing, laser preheating, and in-process 3D scanning. This integration eliminates multiple intermediate steps such as casting, external heat treatment, transport, and re-clamping, directly reducing throughput time and cumulative process deviations.
The working area has been significantly expanded compared with the previous generation. Components with dimensions up to ø 840 × 350 mm or ø 680 × 400 mm can now be processed, representing up to a 170 percent increase in usable workspace. When calculated relative to build volume, this enlargement reduces production costs by more than 70 percent, according to the manufacturer.
A newly developed MultiJet powder nozzle enables uniform material deposition in 5-axis motion, independent of build direction. This design improves powder distribution and contributes to a 35 percent increase in deposition rate, resulting in a reported 47 percent reduction in workpiece cost.
Multi-material capability for functional component design
In addition to infrared laser technology, the system can be equipped with a blue laser source. This expands material compatibility to include highly reflective metals such as copper and enables graded material transitions within a single component. Such transitions allow designers to combine different functional properties, for example integrating copper locally to enhance cooling performance in mold cores.
The process also supports selective deposition of very hard materials exceeding 60 HRC. This enables wear-resistant surfaces or functional zones without additional heat treatment, extending component service life and improving tool performance in applications such as forming and cutting tools.
Process monitoring and digital traceability
To ensure process stability, the machine integrates comprehensive monitoring and control functions through AM Assistant packages. Thermal imaging cameras monitor the surrounding temperature and laser preheating, while optical sensors automatically calibrate and supervise powder mass flow. Additional cameras observe melt pool energy and working distance, enabling closed-loop control of laser power and deposition conditions.
All relevant process data are collected and visualized using a digital evaluation system that represents the build process as a chronological 3D model. This level of traceability supports quality assurance, documentation, and process optimization in regulated or high-value production environments.
Powder handling and machine architecture
Powder is supplied in sealed containers of three sizes—0.5 l, 2.3 l, and 5 l—and stored under argon pressure to ensure safe handling and material integrity. Fine particles are automatically extracted during maintenance access, and optional leak testing and level monitoring further support operational safety.
The machine is based on a rigid monoBLOCK construction, providing positioning accuracy of 4 µm and improved volumetric accuracy through advanced compensation systems. Large access doors facilitate ergonomic operation and crane loading, supporting both manual and automated workflows.
Control is handled via a modern CNC platform with integrated manufacturing cycles, enabling efficient programming and operation even for complex hybrid processes.
From additive capability to industrial production
By combining additive manufacturing, precision machining, and digital process control in a single system, the second-generation hybrid platform addresses key barriers to industrial adoption of additive manufacturing. The integration of multiple processes, expanded material capabilities, and enhanced process stability positions hybrid complete machining as a practical solution for series production, repair, and functional component manufacturing.
