Fully integrated process chains with real-time control and stability
The aviation & space industry is currently experiencing impressive momentum. Following stabilization, the aviation & space industry is experiencing strong growth - driven by the increasing number of flights, passengers and ambitious space projects. This is opening up a wide range of opportunities for companies along the value chain to tap into new markets and bring innovative technologies to series maturity. As growth increases, so do expectations - and this is precisely where the industry's enormous potential lies. Companies are faced with the task of making their production processes flexible and future-proof. The increasing complexity of global supply chains, the highest quality and safety requirements and the need for qualified specialists demand new ways of thinking and innovative solutions.
Initial Situation
Aviation & Space on the upswing
The demands placed on materials and components are extremely high, especially in the aerospace industry. Components must not only withstand extreme loads, but also offer maximum weight efficiency. This combination of lightness and resilience requires innovative materials, precise manufacturing technologies and specialized processing strategies. This is precisely why it is crucial to rely on experienced partners who are not only technological leaders, but also have a deep understanding of the industry-specific requirements. DMG MORI offers a comprehensive portfolio of machines, automation solutions and digital services - combined with decades of experience in aerospace manufacturing.
Although the aviation & space industry is booming, it continues to face major challenges. A key difficulty for manufacturing companies is finding sufficient capacity at suppliers. Partners who can not only meet the necessary certifications and quality standards, but are also able to deliver the most demanding parts and components in the required quantities on time.
The industry is also susceptible to unforeseen events such as raw material shortages, supplier failures or sudden fluctuations in market demand. Companies must therefore be able to adapt their production quickly to avoid downtime. This requires robust and resilient supply chains that can absorb disruptions. In addition, the global nature of supply chains in Aviation & Space complicates the logistical effort.
In addition, competitive pressure is forcing companies to continuously invest in future-proof technologies. The adaptation of production methods, the integration of digital solutions and the development of innovative products often represent a considerable financial burden.
DMG MORI supports companies as an experienced partner in all phases of production: from the feasibility analysis and economic feasibility studies to the installation of the machines, including customized application technology and a comprehensive after-sales service. We are the leading partner for the aviation & space industry: "Such partnerships are already essential in production, where a large proportion of investments are made," says Michael Kirbach. The cooperation with aircraft and engine manufacturers makes aviation an undisputed focus sector for DMG MORI.
Quality and safety first and foremost
The aviation & space industry is regarded as a driving force for technological excellence. Requirements for precision, quality and safety set standards - not only within the sector, but also for many other branches of industry. Materials and components must be able to withstand extreme loads and at the same time meet the highest lightweight construction requirements, which is reflected in high safety standards, comprehensive quality controls and a zero-defect tolerance. For aerospace certifications and approvals, each production step also requires comprehensive documentation and complete traceability of the components in the supply chain. "Certifications such as AS9100 for the production of new aviation components ensure the highest quality standards. In addition, the requirements for high cost-effectiveness are enormous because small batch sizes with high variance dominate," says Kirbach.
In addition, manufacturers aim to further develop spacecraft and aircraft, their propulsion systems and satellites in order to further reduce energy consumption and emissions. These projects are likely to become increasingly important in the industry, which can be described as a driving force, in the coming years and will be guided by legal regulations.
High demands on production
Due to the need to produce small to medium quantities, often with high variance, the demands on production are high. Very flexible systems are usually used: On the one hand, stable machines with high-torque spindles for difficult-to-machine materials such as titanium and nickel alloys, and on the other, dynamic machines with powerful and fast spindles for easy-to-machine materials or aluminum alloys. The combination of the respective material and often complex geometries, for example with low wall thicknesses, can pose many material-specific challenges, such as distortion due to residual stresses.
Value Added
Technology drivers in the aviation & space industry
DMG MORI offers companies in the Aviation & Space sector a wide range of customized solutions tailored to the high standards and requirements of the industry. Our range includes high-precision machine tools specifically designed for the machining of complex components. They are ideal for processing materials such as titanium, aluminum and composite materials, which are preferred in the airframe due to their lightness and strength. The same applies to the machining of Ni-based alloys, which withstand the high mechanical and, above all, thermal loads in the engines. DMG MORI also offers comprehensive process solutions that increase production efficiency. This includes the integration of modern CAD/CAM systems and advanced automation solutions that optimize the production process and make it more efficient.
"We only use the highest quality steel, titanium and aluminum alloys," explain Thomas Heinrich and Steffen Rössner, both responsible for programming in mechanical production at Airbus Helicopters, a long-standing customer of DMG MORI. As these are exclusively safety-relevant workpieces, machining is carried out in frozen processes. "This means that once components and their manufacturing processes have been certified, nothing can be changed - neither programs nor tools."
An important part of our offering is additive manufacturing: DMG MORI's innovative approach to hybrid machining combines conventional manufacturing processes with 3D printing processes, which can be used to make product development more flexible and creative. We offer our customers digital solutions that enable comprehensive networking and real-time monitoring of production processes. With IoT technologies and data-based analysis, companies can increase their efficiency and reduce maintenance costs at the same time. Our portfolio is complemented by excellent global service and support, which ensures that machines are always ready for use and production downtime is minimized. This holistic offering from a single source makes DMG MORI a leading partner for the Aviation & Space sector.
"The combination of laser deposition welding and 5-axis simultaneous milling on the LASERTEC 65 DED hybrid has sustainably optimized our processes in prototype construction," believes Takuya Honda, Plant Manager at AeroEdge Co, Ltd. The company, which manufactures prototypes and series parts for customers in the aerospace industry, sees additive manufacturing as a key technology for the future - and relies on DMG MORI for this.
Your advantages as a customer of DMG MORI
As a DMG MORI customer, you benefit from our many years of experience in the Aviation & Space sector. Our complete solutions include premium machines such as the duoBLOCK series (e.g. DMU 80 P duoBLOCK, DMC 125 FD duoBLOCK), which is ideal for machining complex geometries such as engine housings, landing gear and structural components, which are frequently found in the aviation industry. The CTX series, such as the CTX gamma 1250 TC, offers high-precision turning and is designed for machining rotationally symmetrical parts such as shafts and ring-shaped engine components. Thanks to maximum precision and flexibility, machines such as the monoBLOCK series or larger portal machines are also ideal for the production of small to very large structural components and other demanding parts. In addition to the machine products, we offer customized machine options that are essential for customers depending on the process or specification, as well as all associated process and software solutions.
DMG MORI customers also receive a wide range of services: Our comprehensive service and support services as well as our presence in over 40 countries worldwide ensures that companies can always make optimum use of their machines.
Product
NLX 2500
Ultimate Performance for Parts Machining
Max. workpiece diameter
460 mm
Max. workpiece length
1,255 mm
Max. bar capacity diameter
90 mm
Max. X-axis stroke
260 mm
Max. Y-axis stroke
100 mm
Max. Z-axis stroke
1,345 mm
Control & software alternatives
MAPPS Mitsubishi
CTX gamma 2000 TC
Turn & mill machine for 6-sided complete machining
Max. workpiece diameter
700 mm
Max. workpiece length
2,000 mm
Max. bar capacity diameter
127 mm
Max. X-axis stroke
800 mm
Max. Y-axis stroke
420 mm
Max. Z-axis stroke
2,050 mm
Control & software alternatives
SIEMENS
NTX 2500
6-sided machining with Turn & Mill Spindle compactMASTER
Max. workpiece diameter
670 mm
Max. workpiece length
3,135 mm
Max. bar capacity diameter
80 mm
Max. X-axis stroke
675 mm
Max. Y-axis stroke
300 mm
Max. Z-axis stroke
3,062 mm
Control & software alternatives
SIEMENS
MAPPS
Fanuc
MAPPS Fanuc
CMX 1100 V
The solution-based CMX V - from now on with IoTconnector and direct measuring system in standard
Max. X-axis stroke
1,100 mm
Max. Y-axis stroke
560 mm
Max. Z-axis stroke
510 mm
Max. workpiece height
630 mm
Max. workpiece weight
1,000 kg
Max. workpiece length
1,400 mm
Max. workpiece width
560 mm
Control & software alternatives
SIEMENS
HEIDENHAIN
MAPPS Fanuc
NHX 4000
Horizontal machining center with highest stability, precision and dynamics
Max. X-axis stroke
560 mm
Max. Y-axis stroke
560 mm
Max. Z-axis stroke
660 mm
Max. workpiece diameter
630 mm
Max. workpiece height
900 mm
Max. workpiece weight
400 kg
Control & software alternatives
SIEMENS
MAPPS Fanuc
DMU 50 3rd Generation
CNC Universal Milling Machine with swivel rotary table
Max. X-axis stroke
650 mm
Max. Y-axis stroke
520 mm
Max. Z-axis stroke
475 mm
Max. workpiece diameter
630 mm
Max. workpiece height
600 mm
Max. workpiece weight
300 kg
Control & software alternatives
SIEMENS
HEIDENHAIN
MAPPS Fanuc
DMU 85 (FD) monoBLOCK
The monoBLOCK series has a machine concept for every sector
Max. X-axis stroke
935 mm
Max. Y-axis stroke
850 mm
Max. Z-axis stroke
650 mm
Max. workpiece diameter
1,040 mm
Max. workpiece height
590 mm
Max. workpiece weight
1,500 kg
Control & software alternatives
SIEMENS
HEIDENHAIN
DMU 95 monoBLOCK
The monoBLOCK series has a machine concept for every sector
Max. X-axis stroke
950 mm
Max. Y-axis stroke
850 mm
Max. Z-axis stroke
650 mm
Max. workpiece diameter
1,040 mm
Max. workpiece height
590 mm
Max. workpiece weight
1,000 kg
Control & software alternatives
SIEMENS
HEIDENHAIN
DMU 80 (FD) eVo
Universal Machining Center
Max. X-axis stroke
800 mm
Max. Y-axis stroke
650 mm
Max. Z-axis stroke
550 mm
Max. workpiece diameter
830 mm
Max. workpiece height
600 mm
Max. workpiece weight
600 kg
Control & software alternatives
SIEMENS
HEIDENHAIN
DMC 80 U (FD) duoBLOCK
With the new duoBLOCK series, every component becomes a masterpiece.
Max. X-axis stroke
800 mm
Max. Y-axis stroke
1,050 mm
Max. Z-axis stroke
850 mm
Max. workpiece diameter
900 mm
Max. workpiece height
1,450 mm
Max. workpiece weight
1,400 kg
Control & software alternatives
SIEMENS
HEIDENHAIN
DMC 125 U (FD) duoBLOCK
With the new duoBLOCK series, every component becomes a masterpiece.
Max. X-axis stroke
1,250 mm
Max. Y-axis stroke
1,250 mm
Max. Z-axis stroke
1,000 mm
Max. workpiece diameter
1,250 mm
Max. workpiece height
1,600 mm
Max. workpiece weight
2,000 kg
Control & software alternatives
SIEMENS
HEIDENHAIN
DMU 200 Gantry
Dynamic Gantry design machine for the machining of large workpieces
Max. X-axis stroke
4,000 mm
Max. Y-axis stroke
2,000 mm
Max. Z-axis stroke
1,200 mm
Max. workpiece height
1,250 mm
Max. workpiece weight
20,000 kg
Max. workpiece length
4,300 mm
Max. workpiece width
2,000 mm
Control & software alternatives
SIEMENS
HEIDENHAIN
LASERTEC 65 DED hybrid
Hybrid Complete Machining: Additive Manufacturing and Milling in one Machine
Max. X-axis stroke
735 mm
Max. Y-axis stroke
650 mm
Max. Z-axis stroke
560 mm
Laser power standard
3,000 W
Max. workpiece weight
600 kg
LASERTEC 3000 DED hybrid
Hybrid Machining: Additive Manufacturing and Turning / Milling in one Machine
Max. X-axis stroke
675 mm
Max. Y-axis stroke
300 mm
Max. Z-axis stroke
3,062 mm
Laser power standard
3,000 W
DMU 65 (FD) monoBLOCK 2nd Generation
The monoBLOCK series, a machine concept for every sector
Max. X-axis stroke
735 mm
Max. Y-axis stroke
650 mm
Max. Z-axis stroke
560 mm
Max. workpiece diameter
840 mm
Max. workpiece height
500 mm
Max. workpiece weight
1,000 kg
Control & software alternatives
SIEMENS
HEIDENHAIN
DMU 75 monoBLOCK 2nd Generation
The monoBLOCK series, a machine concept for every sector
Max. X-axis stroke
750 mm
Max. Y-axis stroke
650 mm
Max. Z-axis stroke
560 mm
Max. workpiece diameter
840 mm
Max. workpiece height
500 mm
Max. workpiece weight
600 kg
Control & software alternatives
SIEMENS
HEIDENHAIN
Workpiece examples
Future Orientation
Corporate strategy
The Machining Transformation (MX) strategy, which combines process integration, automation, Digital Transformation (DX) and Green Transformation (GX), is DMG MORI's response to the changing needs of society every ten years. With the MX strategy, DMG MORI is pursuing the goal of promoting sustainability, counteracting the shortage of skilled workers with the help of automation and promoting top talent through extensive training programs in digitalization. On the one hand, more and more work steps - milling, turning, grinding, measuring, etc. - are taking place in a single set-up, while flexible automation solutions reduce manual intervention to a minimum. This increases process reliability and relieves the workload on skilled workers who are needed in work preparation and programming. On the other hand, digital products support entire production processes - from order planning and programming to quality control and seamless traceability
Aviation & Space
The aviation & space industry is booming - and this growth is opening up new opportunities and further challenging tasks for manufacturers. Safety is the top priority in the aerospace industry, which is why the demands on manufacturing quality and the quality of the materials used are very high. At the same time, competitive pressure is forcing companies to invest in new technologies, digital solutions and innovative products, which increases the cost pressure on them. In addition, many companies are struggling with raw material shortages, supplier failures and fluctuations in demand, which requires a great deal of flexibility, rapid production adjustments and robust supply chains.
DMG MORI is an experienced partner for companies facing these challenges and supports them in all phases of production: from planning and procurement through to the ongoing operation of the machines.
We are the leading partner for the aviation & space industry.
Media
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