Laser module improves throughput of machining processes

Research Lead, Licensing Opportunity

The Fraunhofer Institute for Material and Beam Technology (IWS) in Dresden has integrated a laser module into the tool station of a milling spindle, improving the throughput of the machining process.

The five-axis, computer-controlled milling centre can now perform two jobs: three-dimensional deposition welding using a 1.5-kilowatt diode laser, and component finishing using 5-axis milling. The two-in-one machining solution is on show at the joint Fraunhofer stand at the EUROMOLD trade show in Frankfurt this week.

“We have linked all the processing steps [….] and implemented them in a single machine with one tool fixture,” said Steffen Nowotny of the IWS in Dresden. The milling center is ideal for performing repairs on mould inserts used to manufacture plastic components, and for machining finely structured surfaces and functional coatings on metal components.

Instead of having to discard damaged precision tools, they can now be returned to the workshop, reprocessed by the laser welding and milling machine, and reused, saving costs and reducing expenditure on new tools.

The combination of laser cladding and milling is also a cost-effective method of manufacturing complex moulds and metal components directly from a 3-D computer aided design model. The system’s automation and multitasking capabilities are particularly suited to aircraft engine maintenance and automobile manufacturing.