Mazak INTEGREX AG

$350,000 - $1,200,000+ Updated 2026-03-13

Key Specifications

Tool Capacity

36-72 tools by base platform

horizontal max diameter

670-700 mm (26.38-27.56 in)

vertical max diameter

1,050-2,300 mm (41.34-90.55 in)

gear methods

Gear skiving, hobbing, and end milling

gear measurement

On-machine measurement with automatic compensation

base platforms

i-250/i-350/i-450 NEO, i-H, i-500, i-630V/6, e-1250V/8, e-1600V/10

Overview

The Mazak INTEGREX AG is a hybrid multi-tasking platform integrating gear machining into the INTEGREX architecture. AG stands for Automatic Gear, combining standard turning, milling, and 5-axis machining with three gear production methods: gear skiving, hobbing, and end milling. This eliminates dedicated gear cutting machines for many applications.

The AG lineup spans multiple base platforms. Horizontal models on the i-250, i-350, i-450 NEO, i-H, and i-500 platforms cover max diameters up to 700 mm (27.56 in). Vertical models include the i-630V/6 AG (1,050 mm) and e-1250V/8 and e-1600V/10 AG for large-diameter work. Full -S and -ST variants are available.

Gear skiving is the primary method, using a dedicated cutter synchronized with C-axis for high-speed gear production. SmoothAi includes dedicated gear machining cycles automating the programming. On-machine gear measurement with automatic compensation closes the quality loop without removing parts for CMM inspection.

Shops can produce geared shafts, splined components, and gear blanks complete in one setup: turn the blank, cut gear teeth, mill additional features, and measure without unclamping. AG machines carry a 15-25% premium over equivalent non-AG base models. Pricing ranges from $350,000 (i-250 NEO AG) to over $1,200,000 (large vertical AG). Specs sourced from Mazak published data.

Full Specifications

Parameter	Value
Horizontal Max Diameter	670-700 mm (26.38-27.56 in)
Vertical Max Diameter	1,050-2,300 mm (41.34-90.55 in)
Gear Methods	Gear skiving, hobbing, and end milling
Gear Measurement	On-machine measurement with automatic compensation
Base Platforms	i-250/i-350/i-450 NEO, i-H, i-500, i-630V/6, e-1250V/8, e-1600V/10
B Axis Range	240° (-30° to +210°) on horizontal
C Axis Rotation	360° continuous with gear synchronization
Milling Spindle Speed	12,000 RPM (20,000 RPM optional on horizontal)
Milling Spindle Taper	HSK-A63 / Capto C6 / CAT 50 by platform
Tool Capacity	36-72 tools by base platform
CNC Control	MAZATROL SmoothAi CNC with gear machining cycles
Chuck Size	Φ55.12″
Max Machining Diameter	Φ90.55″
Max Machining Length	60.2″
Max Machining Height	66.3″

Specifications sourced from mazak.com — verified 2026-03-28

Strengths & Limitations

Strengths

Integrated gear skiving, hobbing, and end milling eliminate dedicated gear cutting machines for many applications
On-machine gear measurement with automatic compensation closes quality loop without CMM
Complete done-in-one: turn blank, cut teeth, mill features, and measure in single clamping
Available across horizontal and vertical INTEGREX platforms from 8 to 50+ inch chuck
SmoothAi includes dedicated gear machining cycles simplifying complex gear programming
15-25% premium over non-AG is much less than adding a dedicated gear cutter
Full -S and -ST variants for gear components requiring back-working or simultaneous cutting

Limitations

Gear skiving cutters are specialized and expensive, adding to total cost of ownership
Gear accuracy may not match dedicated gear grinding for AGMA Class 10+ requirements
Gear programming requires specialized knowledge beyond standard mill-turn training
AG adds complexity to an already complex multi-tasking platform
Gear skiving generates high forces that can affect other features if sequencing is not planned

Best For

Automotive transmission manufacturers producing geared shafts and splined components Aerospace gearbox shops machining flight-critical gear components in done-in-one processing Robotics and industrial machinery manufacturers producing precision integrated gears Job shops with intermittent gear work that cannot justify dedicated gear cutting machines Prototype and low-volume gear manufacturers where single-machine flexibility reduces lead time

Frequently Asked Questions

01 What does an AG cost?

15-25% premium over non-AG base. i-250 NEO AG starts around $350K. Mid-range horizontal $450K-$650K. Large vertical AG can exceed $1.2M. Gear tooling adds $20K-$50K.

02 What types of gears?

Gear skiving for internal and external spur and helical gears. Hobbing for external spur and helical. End milling for larger-module gears. Also produces splines, serrations, and non-standard forms.

03 What gear quality?

Typically AGMA Class 8-10, covering most power transmission and industrial applications. AGMA Class 11+ (aerospace precision) may need dedicated gear grinding after AG machining.

04 How does on-machine measurement work?

Touch probe measures gear tooth profiles and spacing on-machine. Results compared to programmed geometry with automatic offset compensation for next part. Eliminates CMM removal between operations.

05 Can AG be added to existing INTEGREX?

No. AG requires factory-configured hardware including high-speed C-axis synchronization and skiving spindle parameters. Must be ordered at time of purchase; cannot be retrofitted.