From Prototype Cell to Integrated Production Platform
Hybrid additive manufacturing has long promised to shorten the path from concept to finished metal part. The Lasertec 65 DED hybrid 2 from DMG Mori turns that promise into a more industrial reality by combining directed energy deposition (DED), full 5-axis machining and in-process measurement in one production centre. Instead of treating additive and subtractive steps as separate departments, the machine brings laser deposition welding, milling, drilling, turning, grinding, pre-heating and 3D scanning into a single, tightly coordinated workflow. This DED machining integration is designed for cost-efficient production of complex geometries, repair of high-value wear parts and functional coatings using extremely hard materials. By consolidating these capabilities, manufacturers can use the same platform for rapid prototyping and then scale directly into repeatable, high-quality series production without re-engineering the process chain around separate machines and setups.
DED Machining Integration Shrinks Setups and Lead Times
Traditional additive workflows often require multiple machines and fixtures, with each transfer introducing delay and risk. The Lasertec 65 DED hybrid 2 reduces this friction by executing deposition and 5-axis metal cutting in a single setup, eliminating secondary operations such as separate rough machining or post-build finishing on another machine. Its latest Multijet nozzle supports homogeneous 5-axis powder delivery regardless of orientation, while a 35 percent increase in build rate directly cuts deposition time. The enlarged working envelope—up to 840 mm in diameter by 350 mm tall or 680 mm by 400 mm—expands the range of components that can be produced without re-fixturing. Functionality such as laser preheating and grinding is available inside the same clamping. The result is a more compact, predictable process chain that enhances series production capabilities by reducing work-in-progress, setup errors and overall lead time for complex parts.
In-Process Measurement Raises Confidence in Complex Geometries
A key barrier to scaling hybrid additive manufacturing has been confidence in dimensional accuracy and process stability. DMG Mori addresses this with extensive in-process measurement and monitoring embedded in the Lasertec 65 DED hybrid 2. Cameras and sensors track the process in real time: a thermal imaging camera controls temperature during laser preheating and build, while an optical sensor automatically calibrates and monitors powder mass flow. Additional cameras observe melt-pool thermal energy for closed-loop laser power control and maintain the correct working distance between nozzle and workpiece. Beyond the additive process, integrated measuring functions and 3D scanning allow critical features to be verified immediately after machining. AM Evaluator software creates a time-based digital twin, mapping this real-time data onto the 3D model. Combined with the machine’s 4-micron positioning accuracy and volumetric calibration via VCS Complete, these tools help achieve tighter tolerances on intricate geometries in repeat production.
Expanding Material Options and Functional Design Freedom
Beyond process consolidation, hybrid systems are redefining what can be built. The Lasertec 65 DED hybrid 2 offers both infrared and higher-frequency blue laser sources, widening the palette of processable materials to include reflective metals. This enables graded material transitions and functionally optimised structures within a single component. For example, copper can be locally integrated into mould cores to improve cooling performance, while transitions between hard and soft or magnetic and non-magnetic alloys can be tailored for specific use cases. Selective deposition of hard material above 60 HRC extends component life without additional heat treatment steps. These capabilities make the machine well suited for coating and repair strategies that would be impractical with conventional subtractive processes alone. As designers exploit this functional layering and gradient capability, hybrid additive manufacturing becomes a more compelling choice for high-value, series-produced components with demanding performance requirements.