Shaping the future of metal 3D printing with advanced laser precision

At a time when manufacturers are searching for greater efficiency, flexibility, and sustainability, DMG MORI continues to strengthen its position as one of the industry’s most forward-thinking innovators. During its recent Open House in Bielefeld, the company unveiled the LASERTEC 30 SLM 3rd Generation—a completely re-engineered platform that establishes new standards in selective laser melting (SLM) for metal additive manufacturing.

Far more than an incremental update, the new LASERTEC 30 SLM 3rd Gen represents a complete redesign—a product of DMG MORI’s decades of combined expertise in machine tool construction and additive process engineering. Featuring a quad-laser system with full-field overlap and a build volume of 325 × 325 × 400 mm, this machine targets the core of market demand for robust, precise, and repeatable production of complex components.

From Machine Tool Heritage to Additive Excellence

The LASERTEC 30 SLM 3rd Gen draws heavily from DMG MORI’s deep roots in precision machine tool manufacturing. The most striking difference from earlier models—and from much of the competition—is the use of cast iron for the base structure. While this approach is standard in milling and turning centers, it is still rare in the additive world.

By transferring this proven construction philosophy to additive manufacturing, DMG MORI ensures unparalleled rigidity, vibration damping, and long-term accuracy. Casting provides not only mechanical stability but also predictable thermal behaviour—critical for maintaining process consistency across long build cycles and varying environmental conditions.

Thermal Stability Through Intelligent Structural Design

Although additive systems do not experience the same dynamic forces as traditional machine tools, temperature fluctuations present a major source of variation in powder-bed fusion processes. DMG MORI’s engineering team has tackled this challenge with precision.

The LASERTEC 30 SLM 3rd Gen employs a Floating Process Chamber, an isolated unit that expands freely in all directions to compensate for temperature changes. Meanwhile, the optical system is mounted on a rigid gantry frame, ensuring that the distance between the laser optics and the powder bed remains constant. A calibrated recoater referencing system and active Z-axis compensation work together to maintain consistent layer thickness and surface quality. The result is a system that produces uniform layers and reliable part geometries—even over extended builds.

Smart Material Management: The rePLUG Advantage

DMG MORI’s rePLUG system remains one of the most practical solutions in metal additive manufacturing. Each rePLUG module is a fully enclosed powder handling unit that can be swapped in minutes, allowing fast material changeovers and reduced downtime.

For industries where process qualification is crucial—such as aerospace and medical technology—the rePLUG ensures consistent powder integrity by maintaining a fully inert, closed-loop powder circuit. Excess material is automatically sieved, conditioned, and recycled without exposure to air or humidity. This prevents oxidation, maintains flowability, and enhances operator safety.

Combined with improved accessibility for internal cleaning, the LASERTEC 30 SLM 3rd Gen is arguably one of the most flexible additive machines available today. The ability to switch between materials quickly expands its use across multiple applications—from high-performance alloys to lightweight structures and tooling components.

Maximising Uptime and Operator Safety

Efficiency lies at the heart of the new design. For the first time, DMG MORI introduces a quick-change build container system, allowing users to start a new build without waiting for the previous job to cool. Covers stored inside the working chamber seal the build container upon removal, preserving the inert gas environment and enabling an immediate restart.

The process is supported by comprehensive in-situ monitoring. High-resolution cameras continuously inspect the powder bed surface after each layer, detecting potential anomalies before the recoating process begins. In the event of contact with an undetected protrusion, the bi-directional recoater features a collision protection system that detaches instantly, minimising downtime and preventing further mechanical damage.

Optimised Gas Flow and Optical Protection

Gas flow within the process chamber has also been completely reimagined. The newly designed laminar gas stream ensures stable and efficient shielding across the entire powder bed. A secondary flow prevents any residue buildup on the protective glass, maintaining optimal optical clarity during extended builds.

This “wind-tunnel concept” gas management system delivers superior part quality, consistent melt-pool stability, and longer optical component life. A dedicated camera continuously monitors the protective glass, alerting the operator if cleaning is required. Enhanced LED lighting within the optical area further supports visual inspection and maintenance, emphasising ease of use alongside precision.

Human-Centered Operation with CELOS X

While the LASERTEC 30 SLM 3rd Gen is built for industrial performance, DMG MORI has not overlooked the human factor. The integration of the CELOS X operating system transforms machine interaction into a guided, intuitive experience. Operators receive on-screen prompts for each step—from powder refilling and glass cleaning to maintenance routines—ensuring safe, standardised, and efficient workflows.

This approach is particularly valuable for manufacturers integrating additive processes into existing shop-floor environments. By lowering the learning curve and embedding procedural safety, CELOS X helps operators focus on production quality rather than complex setup tasks.

A Step Toward the Future of Hybrid Manufacturing

The LASERTEC 30 SLM 3rd Generation is more than just a new machine; it represents DMG MORI’s broader vision for the industrialisation of additive manufacturing. As production requirements shift toward lightweight, optimised, and geometrically complex components, the synergy between additive and subtractive technologies will become increasingly vital.

With its combination of mechanical precision, intelligent process control, and user-centric design, the LASERTEC 30 SLM 3rd Gen stands as a symbol of how additive manufacturing is maturing—from a prototyping tool to a mainstream production technology.

In redefining the standards of stability, usability, and flexibility, DMG MORI not only strengthens its leadership in metal 3D printing but also sets the stage for the next era of hybrid, data-driven, and sustainable manufacturing.