DN Solutions Metal Additive Manufacturing

DN Solutions DLX 420

$800,000 - $1,400,000 Updated 2026-03-13

Key Specifications

X Travel

420 mm (16.5 in)

Y Travel

250 mm (9.8 in)

Z Travel

900 mm (35.4 in)

Tool Capacity

20 tools

Max Turn Length

900 mm (35.4 in)

max turning diameter

420 mm (16.5 in)

Overview

The DN Solutions DLX 420 is a hybrid additive/subtractive manufacturing machine that combines directed energy deposition (DED) laser cladding with full CNC turning and milling capability on a single platform. This machine represents DN Solutions' entry into the growing hybrid manufacturing space, competing against the DMG Mori LASERTEC 65 DED, Mazak Integrex i-400AM, and Okuma MU-8000V LASER EX.

The DED system uses a high-power fiber laser (typically 2-4 kW) with coaxial powder nozzle to deposit metal layer by layer directly onto a workpiece or substrate. Unlike powder bed fusion (PBF) systems that build in a chamber, the DED process works in the machine's open work envelope, allowing material to be added to existing parts, repair worn components, or build near-net-shape features that are then finish-machined in the same setup. The system supports a range of materials including stainless steels, Inconel, titanium alloys, cobalt-chrome, and tool steels.

The subtractive side runs a turning spindle at 3,000 RPM with 22 kW (30 hp) through a 10-inch chuck, paired with a B-axis milling spindle at 10,000 RPM. Axis travels span approximately 420 mm on X, 250 mm on Y, and 900 mm on Z, with max turning diameter of 420 mm (16.5 in). The machine runs on a FANUC 31i-B5 control with integrated additive process control, managing laser power, powder feed rate, shield gas flow, and deposition path alongside conventional CNC operations.

The hybrid approach is transformative for repair and remanufacturing applications — turbine blade tip repair, die and mold restoration, bearing surface rebuilding, and adding features to existing castings or forgings. New machines price between $800,000 and $1,400,000 depending on laser power, powder delivery configuration, and subtractive machine options. At roughly 12,000 kg (26,455 lb), it's comparable in footprint to a standard multi-tasking turning center. Specs sourced from DN Solutions, industry publications, and hybrid manufacturing technology data.

Full Specifications

Parameter	Value
Max Turning Diameter	420 mm (16.5 in)
Max Turning Length	900 mm (35.4 in)
X-Axis Travel	420 mm (16.5 in)
Y-Axis Travel	250 mm (9.8 in)
Z-Axis Travel	900 mm (35.4 in)
B Axis Range	240° (+/-120°)
Turning Spindle Speed	3,000 RPM
Turning Spindle Power	22 kW (30 hp)
Milling Spindle Speed	10,000 RPM
Chuck Size	10 in
Laser Type	Fiber laser (DED)
Laser Power	2-4 kW (configuration dependent)
Deposition Method	Coaxial powder nozzle, directed energy deposition
Deposition Materials	Stainless steels, Inconel, titanium alloys, cobalt-chrome, tool steels
Deposition Rate	Up to 2 kg/hr (material dependent)
Tool Capacity	20 tools
Machine Weight	12,000 kg (26,455 lb)
CNC Control	FANUC 31i-B5 with integrated additive process control
Metric	IMPERIAL

Specifications sourced from dn-solutions.com — verified 2026-03-28

Strengths & Limitations

Strengths

True hybrid additive/subtractive capability enables building, repairing, and finishing complex metal parts in a single setup — eliminating the multi-machine workflow of standalone DED + CNC machining
DED process supports a wide range of materials including Inconel, titanium, cobalt-chrome, and tool steels, with the ability to deposit dissimilar materials for functionally graded components
Repair and remanufacturing applications provide immediate ROI — turbine blade tip repair, die restoration, and worn component rebuilding can justify the machine on a single contract
Full CNC turning and milling capability with B-axis means the machine functions as a standalone multi-tasking center when additive operations aren't needed
Coaxial powder nozzle DED deposits material at rates up to 2 kg/hr, far faster than powder bed fusion for adding bulk material to existing parts

Limitations

High acquisition cost of $800K-$1.4M is a significant investment, and the machine requires ongoing powder material costs, laser maintenance, and specialized operator training
DED surface finish is rough (typically Ra 10-25 micrometers) and always requires finish machining, adding cycle time compared to subtractive-only approaches for parts that can be machined from billet
Powder utilization efficiency of 30-60% means significant material waste compared to powder bed fusion systems with 95%+ utilization, increasing per-part material costs
Limited installed base means fewer application engineers, service technicians, and reference shops to consult when developing new hybrid processes

Best For

Aerospace MRO facilities repairing turbine blades, vanes, and combustion components where DED cladding restores worn surfaces followed by precision finish machining in the same setup Die and mold shops repairing and modifying expensive tooling by adding material to worn surfaces, damaged areas, or design changes without scrapping the entire tool Research and development teams exploring functionally graded materials, multi-material deposition, and novel manufacturing approaches that combine additive and subtractive processes Energy sector shops remanufacturing high-value rotating components like turbine shafts, bearing journals, and pump impellers where the cost of a new part far exceeds repair costs

Frequently Asked Questions

01 What does a new DN Solutions DLX 420 cost?

New DLX 420 machines typically price between $800,000 and $1,400,000 depending on laser power, powder delivery system configuration, and subtractive machine options. Higher-power laser options and multi-powder delivery systems increase the price. That's competitive with the DMG Mori LASERTEC 65 DED ($1M-$1.5M+) and positions the DLX 420 as a more accessible entry into hybrid manufacturing.

02 What materials can the DLX 420 deposit?

The DED system supports stainless steels (316L, 17-4PH), nickel superalloys (Inconel 625, 718), titanium alloys (Ti-6Al-4V), cobalt-chrome (CoCr), and tool steels (H13, M2). Material qualification is application-specific and may require process development. The coaxial powder nozzle can also deposit dissimilar materials for functionally graded or multi-material components.

03 How does DED compare to powder bed fusion for manufacturing?

DED builds much faster (up to 2 kg/hr vs grams/hr for PBF) and works on existing parts for repair and feature addition. However, DED produces rougher surfaces requiring finish machining and has lower powder utilization (30-60% vs 95%+ for PBF). DED excels at repair, large feature addition, and building on existing substrates. PBF excels at complex geometries, fine features, and small parts from scratch.

04 Can the DLX 420 be used as a standard CNC when not doing additive?

Yes. When the laser head is retracted and stored, the machine operates as a conventional multi-tasking CNC turning and milling center with B-axis capability. This dual-use capability helps justify the investment for shops that don't run additive operations full-time — the machine earns revenue as a standard CNC between additive jobs.