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The Integrex i-400 AM integrates Direct Energy Deposition additive manufacturing technology into a 5-axis Multi-Tasking machine to offer machine users hybrid technology, combining the benefits of additive and subtractive manufacturing into one platform.

The Integrex i-400 AM makes use of a built-in 1kW fiber laser to melt metallic powder, which is then applied layer by layer via interchangeable cladding heads. These heads are stored in the machine’s standard 36-tool magazine and provide the ability to automatically change between additive and subtractive tooling, optimising process cycle time. Once the additive manufacturing process is complete, the machine’s Multi-Tasking capability finishes the component.

The latest generation of the Integrex i-400 AM incorporates a full A and C axis NC Table providing the capability to both machine or clad simultaneously in full 5-axis, further enhancing the application geometry that can be generated.

The Integrex i-400 AM technology can be used to clad a range of material types, including stainless steel, nickel alloys and copper. This capability to cover a variety of materials makes the machine suitable for a range of applications, from repairing existing worn or damaged components, to the addition of critical features or the complete generation of new parts.

The Integrex i-400 AM will be exhibited with two new high-performance heads, a high-speed cladding head for high rate material deposition delivering a bead size of 3 x 1mm and a fine cladding head for more intricate feature generation with a bead size of 1 x 0.5mm, providing robust process flexibility to meet a range of application requirements.

The Integrex i-400 AM, which is now available with SmoothX control, has full 5-axis machining capability to efficiently process prismatic, round and highly contoured work pieces, as well as those near net features which have been created using the integrated additive technology. Finished parts can also be laser marked if necessary using the same head technology.

The Integrex i-400 AM has 50m/min rapid traverse rates, a main spindle capable of delivering 3,300rpm/30kW and a 12,000rpm/22kW milling spindle.

The Integrex i-400 AM incorporates Mazak’s latest generation of CNC, SmoothX, which has been ergonomically designed with the operator in mind. The operating panel boasts a 19in touch screen, and can be tilted and rotated to suit the posture of the operator.

The new ‘Quick Mazatrol’ interface also reduces the number of keystrokes to write a conversational program by 38 per cent compared to its predecessor. Control of both subtractive machining and additive cladding is fully integrated into the control providing a single ergonomically designed interface from which the operator can easily program and oversee all applications.

Yamazaki Mazak Ltd

Yamazaki Mazak is the world’s largest manufacturer of computer controlled (CNC) metal-cutting machines. With over 260 different models, the Mazak product range includes CNC lathes, machining centres, multi-tasking machines and flexible manufacturing systems as well as laser processing machines.

Machine tools are called “Mother Machine” because they relate to the manufacturing of almost every product around us and are very important in supporting the base of “world manufacturing.” Our mission as a machine tool maker is to enrich people’s lives and contribute to society by developing and providing high performance machine tools that can produce high accuracy work in a short time.

We were among the first to start foreign production as a Japanese machine tool maker. Following the establishment of Mazak Corporation in the USA, we expanded our production base worldwide to include the UK, Singapore and China, as well as further expanding our Japanese manufacturing operations. We are the only machine tool maker to have established a global production system. With these local plants, we have been able to provide high quality service and have built strong relationships based on mutual trust with customers from all over the world.

True to the Yamazaki principle of supporting the customer locally, Mazak’s European Manufacturing plant, in Worcester UK, opened in June 1987 and was immediately recognised as the most advanced machine tool manufacturing plant in Europe. The factory has expanded three times since then and now offers over 29,000m2

This is a complete machine tool manufacturing plant. Mazak machines the components that go to make its spindles, turrets, tool magazines and Mazak even manufactures its own sheet metal covers. As with all Mazak manufacturing plants, the most rigorous practices and Kaizen programmes ensure continuous improvement.

Serving all of Europe’s markets, more than 80% of the machine tools built in Worcester are exported from the UK into Europe. More than 17,000 Mazak machines have been manufactured here so far and this number continues to grow every day.

Mazak European Manufacturing Plant is recognised for its factory automation, technology and overall management practices. Selected as one of the “Top Ten Companies in the World” by the Swedish Royal Academy of Science and Technology underscores this worldwide reputation.

As with all Mazak factories, this facility comprises a variety of flexible manufacturing systems, consisting of machining centres, multi-tasking CNC lathes, and a sheet metal FMS – all designed for unmanned operation.

The plant benefits from highly skilled employees who are committed to continuous improvement through the 25 “Kaizen” teams in operation.

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