The Mazak INTEGREX i-400AM HYBRID Multi-Tasking machine applies additive and subtractive technologies in the most optimized way possible. It offers turning, milling, drilling, metal deposition and laser marking in a single setup. Together, these operations provide several unique advantages such as significantly reduced part cycle times and the ability to process highly complex workpiece geometries that we previously impossible.

Well suited for processing parts from difficult-to-machine metals in small lots, the INTEGREX i-400AM makes it possible to quickly and easily grow part features instead of losing valuable time and wasting expensive materials by subtracting large amounts of metal from a solid material.

The INTEGREX i-400AM features dual laser cladding heads, or additive manufacturing nozzles, that provide options for high rate and fine metal deposition. Essentially, these two cladding heads complement each other much like roughing and finishing tools work together in chip making. The cladding heads reside in the tool magazine with the machine’s automatic tool changer ready to load/unload them into/from the milling turret as needed. Furthermore, the machine is the only hybrid machine on the market able to automatically change its deposition heads.

During operation, the INTEGREX i-400AM uses fiber laser heat to melt the chosen metal powder that will be used to the grow near-net-shape 3D forms. The cladding heads apply the molten material layer by layer, each of which solidifies as the desired part surface or features grows. Specific part examples include ribs, tubular extensions, fan blades and flanges. It is also possible to generate new part features in a material that is harder or lighter than the parent workpiece material.

Furthermore, the laser cladding heads can be used to coat chosen sections of the part with metal, allowing the machine to repair worn or damaged high-value components such as turbine blades.

Once the part features are grown to near net shapes, the INTEGREX i-400AM then applies one or more of its advanced subtractive processes, including full 5-axis milling, turning, hobbing and contouring, to process the part complete. The machine features a B-axis movement of -30/+210 degrees in its milling spindle, full C-axis contouring with its turning spindle and a fully programmable second spindle for DONE IN ONE® production.

Perfect for high-volume job shops as well as aerospace and construction manufacturers, the Mazak INTEGREX e-1250V/8 Multi-Tasking machine combines full 5-axis milling, powerful turning and pallet changing to productively process complex parts up to 57″ in diameter and 63″ high in single setups.

The machine employs a 10,000-rpm, 50-hp milling spindle with a B-axis tilt of -30/+120 degrees for accurate 5-axis operations, while a 500-rpm, 54-hp direct-drive C-axis turning table with roller gear cam technology eliminates backlash for smoother, high-precision rotation in heavy-duty cutting operations. High-speed and high-torque milling spindle specifications are also available so the machine can successfully meet a broad range of application requirements involving materials such as titanium, aluminum and steel.

Mazak situated the machine’s automatic tool changer, available in tool storage capacities of 42, 84, 120 or 162 tools, near the CNC so operators can perform quick visual tooling checks. Such positioning also puts the cutting tools closer to the spindle for faster change outs. Furthermore, this high-speed, rack-type tool magazine is expandable after the machine’s initial installation. Axis travels on the INTEGREX e-1250V/8 measure 73.82″ in X, 49.21″ in Y and 52.95″ in Z. The axes incorporate Mazak’s MX Hybrid Roller Guide System to achieve high levels of durability and reliability that result in long-term accuracy. The innovative way system increases vibration dampening, extends tool life, handles higher load capacities and eliminates tramp oil in the coolant via a greener grease-based lubrication system.

The machine features Mazak’s all-new MAZATROL SmoothX CNC, which offers the industry’s fastest processing capabilities. As a key component of the company’s new SMOOTH TECHNOLOGY process-performance platform, the CNC offers several productivity advantages that reduce machining cycle times, especially in fine increment programs for simultaneous 5-axis operations and free-form die-mold machining. Highly beneficial to part manufacturers focused on high-volume production, the INTEGREX e-1250V/8 comes with a two-pallet changer that provides unattended operations and off-cycle part setup. This simple, efficient form of automation allows operators to load, unload and inspect parts on one pallet while the machine works on the other undisturbed.

For those seeking lights-out operations, the machine also integrates with the company’s PALLETECH System, an advanced pre-engineered palletized manufacturing solution.

Mazak Corporation has unveiled its new INTEGREX i-400AM (additive manufacturing) HYBRID Multi-Tasking Machine. As a fusion of additive technology and Mazak’s most advanced Multi-Tasking capabilities, the machine will significantly reduce part cycle times while providing high-efficiency Done-In-One® processing.

As a turnkey system, the INTEGREX i-400AM offers manufacturers a new innovative alternative to conventional processing in terms of part design and machining. The technology is especially well suited for small lot production of very difficult-to-cut materials such as those used in the aerospace, energy and medical industries. With the additive capability, manufacturers can easily generate/clad near-net-shape component features then quickly complete them with high-precision finish machining operations – as well as laser mark parts if needed.

In operation, the INTEGREX i-400AM melts metal powder using fiber laser heat. Cladding heads (additive manufacturing nozzles) 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, a capability beneficial in the efficient repair of existing worn or damaged components, such as aerospace turbine blades.

Cladding heads store in the INTEGREX i-400AM’s tool magazine, and the standard automatic tool changer loads them into the machine’s milling turret. Mazak offers two types of cladding heads – high speed or high accuracy. Users select the appropriate head based on the intended process and the particular metal powder to be used.

On the Multi-Tasking machine side, the INTEGREX i-400AM provides full 5-axis capability to easily 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.