Hybrid Manufacturing Systems And Additive Production Technologies Unveiled

DMG MORI is presenting hybrid manufacturing systems and additive production processes at Formnext, taking place in Frankfurt from November 17 to 20, 2026. The technologies showcased in Hall 12 at Booth D139 aim to optimise repair, coating, and manufacturing processes in the aerospace, medical technology, and semiconductor industries.

Core Technology And System Architecture
The technological presentation centres on the second-generation LASERTEC 65 DED hybrid and the third-generation LASERTEC 30 SLM. The system architecture of the DED hybrid machine integrates up to six processes in a single workspace, including directed energy deposition via powder nozzle, 5-axis simultaneous milling, turning, grinding, laser-based preheating, and optical scanning using the scan3D sensor. The SLM powder bed process utilises a thermo-symmetric machine concept and up to four overlapping lasers, complemented by an exchangeable build container with a build volume of 325 by 325 by 400 millimetres. These hardware components function as end-to-end manufacturing solutions to build complex geometries and perform material deposition as well as subtractive post-processing without reclamping.

Deployment And Implementation
The implementation of these additive and hybrid machines requires integration into existing industrial manufacturing chains. Deployment is supported by the ADDITIVE INTELLIGENCE consulting unit, which assists with structural design and production ramp-up based on experience from in-house component manufacturing. During the trade fair, specialists will evaluate specific requirements for monitoring process parameters using sensors and cameras. The use of the multi-jet nozzle and the closed powder circuit are implemented directly into the system architecture to ensure process reliability during material deposition.

Industrial Applications
The showcased manufacturing solutions are targeted at industrial series production, aerospace, medical, and semiconductor sectors. Concrete technical use cases include the economical repair of highly stressed wear parts and the coating of workpieces with hard materials in a single setup. The use of the scan3D sensor enables automated comparison with target data sets for the precise identification of damaged areas. Providing these combined additive and subtractive processes ensures high dimensional accuracy, minimises the risk of stress cracks during material deposition, and improves the reproducibility of quality-critical components.




Operational Impacts And Performance Metrics
Integrating hybrid processes significantly reduces lead times compared to conventional manufacturing chains and lowers workpiece costs for the LASERTEC 65 DED hybrid by 47 per cent. Increasing the build rate by 35 per cent and enlarging the workspace for workpieces up to 840 millimetres in diameter maximises the productivity of the system. For the LASERTEC 30 SLM, the exchangeable build container reduces setup times for subsequent orders, while the closed handling concept reduces inert gas consumption, enabling plant operators to achieve higher availability and process stability in industrial manufacturing.

Edited by Maria Brueva, Induportals editor - adapted by AI.

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