DMG MORI UK, the British division of machine tool manufacturer DMG MORI, has introduced the LASERTEC 65 DED hybrid 2, a second-generation production centre combining directed energy deposition (DED) with 5-axis machining and measurement in a single setup.
Launched earlier this year at the company’s open house in Pfronten, southern Germany, the system is designed for producing complex metal components, repairing worn parts, and applying hard material coatings to workpieces. The machine integrates additive manufacturing with milling, drilling, turning, grinding, pre-heating, and 3D scanning.
Hybrid DED machining for complex metal parts
The LASERTEC 65 DED hybrid 2 builds on DMG MORI’s monoBLOCK machine platform and is intended to support industrial metal additive manufacturing workflows where deposited material must be machined to final tolerances.
According to the company, the system’s latest MultiJet nozzle enables 5-axis material deposition with homogeneous powder distribution, regardless of powder flow orientation. DMG MORI says the machine increases build rate by 35% compared with the previous generation, while offering a build volume that is 170% larger.
The working area can accommodate parts up to 840 mm in diameter by 350 mm tall, or 680 mm in diameter by 400 mm tall. Axis positioning accuracy is listed at 4 microns, supported by VCS Complete, a calibration technology cycle app that covers the full working volume.
The system runs within DMG MORI’s CELOS X control environment, which is integrated with the Siemens SINUMERIK ONE control.
Blue laser option expands material range
Alongside infrared laser technology, the LASERTEC 65 DED hybrid 2 can be equipped with a higher-frequency blue laser source. This option is intended to process reflective metals and enable graded transitions between different materials.
DMG MORI identifies copper as one example, noting that it can be used to improve the cooling performance of plastic injection or die casting mould cores. The machine can also be used to create gradients between hard and soft metals, or between magnetic and non-magnetic materials.
Selective application of hard materials above 60 HRC is intended to extend component service life without requiring additional heat treatment.
Process monitoring and powder handling
The machine includes AM Assistant packages for process monitoring using cameras and sensors. A thermal imaging camera monitors temperature in the working area and during laser preheating, while an optical sensor automatically calibrates and monitors powder mass flow.
Additional monitoring systems track melt pool thermal energy for closed-loop laser power control and check the working distance between the nozzle and the workpiece. AM Evaluator software generates a time-sequenced digital twin, mapping process data onto a 3D model of the component.
Metal powder is supplied in argon-pressurized containers available in 0.5 litre, 2.3 litre, and 5 litre sizes. For operator safety, an automated extraction system removes fine particulates from the DED module when the conveyor access door is opened. Optional pressure leak checking and a level sensor can also be integrated.
Wide doors provide access to the work area for crane loading and unloading, while also supporting the addition of automation systems.
Hybrid additive and subtractive manufacturing
DMG MORI has previously positioned its LASERTEC DED hybrid systems integrated with additive and subtractive processes within automated production workflows. At Formnext 2025, the company highlighted how combining milling, turning, grinding, preheating, laser deposition welding, and 3D scanning in one machine can reduce lead times and avoid external rework steps. Blue laser technology and graded material transitions were identified as ways to expand the use of hybrid systems for reflective metals and higher-performance components.
Hybrid manufacturing has also been applied outside metal DED. Hybrid Manufacturing Technologies Global’s AMBIT XTRUDE system, shown during Trident Warrior 2025, added pellet-fed polymer extrusion to a Navy-owned CNC machine before switching back to milling for finishing. While the process and materials differ from DMG MORI’s LASERTEC 65 DED hybrid 2, both examples point to manufacturers’ efforts to add 3D printing capability without separating it from established machining workflows.
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Featured image shows The LASERTEC 65 DED hybrid 2 from DMG Mori. Image via DMG Mori.
