From Experimental Cells to Production-Ready 3D Printing
Hybrid additive manufacturing is rapidly shifting from a niche prototyping tool to a genuine production technology. By combining directed energy deposition (DED) with mature 5‑axis machining and in‑process measurement inside a single system, manufacturers can build, finish, and verify complex metal parts in one continuous workflow. This tight DED machining integration removes the need to shuttle components between separate 3D printers, CNC machines, and metrology stations, cutting lead times and reducing tolerance stack‑ups. Instead of treating additive as a standalone process, hybrid machines embed it directly into the metal‑cutting environment, enabling production‑ready 3D printing that fits established shop practices. The result is a more predictable pathway from digital model to certified part, where geometry can be added, machined, and checked without leaving the machine envelope. That integration is what finally makes additive compelling for series production rather than just one‑off prototypes.
Inside the Lasertec 65 DED Hybrid 2: Additive, Machining, and Measurement in One
DMG Mori’s second‑generation Lasertec 65 DED hybrid 2 exemplifies how hybrid additive manufacturing is being engineered for industrial use. In a single setup, the machine performs laser deposition welding via a powder nozzle, full 5‑axis milling and drilling, turning, grinding, pre‑heating, and 3D scanning. It integrates in‑process measuring to verify geometry without external quality control stations, supported by a rigid Monoblock construction and a positioning accuracy of 4 microns. Build capability has expanded significantly, with a 170 percent larger build volume supporting workpieces up to 840 mm in diameter by 350 mm tall or 680 mm by 400 mm. A proprietary Multijet nozzle enables homogeneous 5‑axis material deposition regardless of orientation, while a blue laser option extends process capability to reflective metals and graded material transitions. All of this runs under the Celos X control environment with VCS Complete calibration, reinforcing process stability at production scale.
Eliminating Post-Processing Through Closed-Loop, In-Process Measurement
A key enabler for factory‑floor hybrid additive manufacturing is in‑process measurement and monitoring. The Lasertec 65 DED hybrid 2 uses integrated sensors and cameras to keep the process in control as material is added and removed. Powder mass flow is automatically calibrated and monitored by an optical sensor, while a thermal imaging camera supervises the temperature in the working area and during laser preheating. Another camera tracks the melt pool’s thermal energy, feeding closed‑loop control of laser power, and a further camera continuously checks the working distance between nozzle and workpiece. On top of this, AM Evaluator software maps time‑sequenced process data onto a 3D model, effectively creating a digital twin of each build. Coupled with on‑machine dimensional probing, this level of in‑process measurement reduces the need for separate inspection operations and allows manufacturers to achieve tight tolerances directly on the hybrid system.
New Applications: Complex Parts, Repairs, and Functional Coatings
By uniting DED, machining, and metrology, hybrid systems unlock applications that are hard or impossible to tackle with conventional routes. Complex part production becomes more efficient because near‑net geometries are additively built and then finished with high‑precision 5‑axis machining in the same setup. For repair work, worn or damaged areas on high‑value components can be rebuilt additively and then re‑machined to nominal dimensions, extending service life without scrapping the entire part. Hybrid additive manufacturing is also well suited to precision coatings and graded structures. The Lasertec 65 DED hybrid 2 can apply extremely hard materials exceeding 60 HRC selectively, avoiding separate heat treatment, or create transitions between hard and soft or magnetic and non‑magnetic metals. For example, copper can be integrated into mould cores to improve cooling performance, demonstrating how functional material tailoring is moving into routine production.
Process Integration Brings Additive to the Factory Floor
The broader significance of DED machining integration lies in process consolidation and shop‑floor practicality. Hybrid machines like the Lasertec 65 DED hybrid 2 condense what used to be a multi‑stage, multi‑machine route—3D printing, heat treatment, rough and finish machining, and off‑line inspection—into a unified production cell. This integrated approach reduces handling, fixtures, and queuing, while minimising geometric deviations caused by repeated reclamping. It also simplifies automation, as wide access doors and crane‑friendly layouts ease integration with robotic loading systems. With improved build rates—DMG Mori reports a 35 percent increase compared to the previous generation—and enhanced powder handling and extraction for operator safety, hybrid additive manufacturing is becoming a realistic choice for series production. As these systems mature, the line between additive and subtractive manufacturing blurs, replaced by a single, data‑rich process chain tuned for high‑mix, complex‑geometry part production.