Mazak INTEGREX i-100S

$280,000 - $380,000 Updated 2026-03-16

Key Specifications

Tool Capacity

36 tools standard (72 optional)

max machining diameter

450 mm (17.7 in)

max machining length

670 mm (26.4 in)

bar capacity

51 mm (2.0 in)

main chuck size

6 in (A2-5 spindle nose)

main spindle speed

5,000 RPM

Overview

The Mazak INTEGREX i-100S is the compact entry point to the INTEGREX i-series multi-tasking platform, adding a second spindle (the S designation) for complete done-in-one processing of small-to-medium bar and chuck parts. Where the standard i-100 provides a single main spindle with tailstock, the i-100S replaces the tailstock with a fully functional second turning spindle, enabling simultaneous front and back machining and complete part processing in a single machine cycle.

The i-100S accommodates 51 mm (2.0 in) bar capacity with a 6-inch main chuck and a sub-spindle chuck. Maximum machining diameter is 450 mm (17.7 in) and maximum machining length is 670 mm (26.4 in). The main turning spindle delivers 18.5 kW (25 hp) at 5,000 RPM through an A2-5 spindle nose. The milling spindle operates at up to 12,000 RPM with 11 kW (15 hp) through an HSK-A40 interface, providing full machining center capability for milling, drilling, and tapping on any surface of the workpiece.

The B-axis swings 240 degrees (-30 to +210 degrees) with roller cam drive and 0.0001-degree indexing resolution, enabling true 5-axis simultaneous machining in the milling spindle. The Y-axis provides 100 mm (3.94 in) of off-center travel for all driven tool operations. The standard ATC holds 36 tools with magazine options up to 72 tools.

The i-100S runs on MAZATROL SmoothAi control. New machine pricing runs $280,000 to $380,000 depending on ATC configuration and options. The machine competes with the DMG Mori NTX 1000, the Okuma Multus B200II, and the Doosan Lynx 2100LSYB in the compact mill-turn class. It is particularly valued in medical device, aerospace fastener, and precision instrument manufacturing segments where part completeness and accuracy in a small machine footprint are both critical.

Full Specifications

Parameter	Value
Max Machining Diameter	450 mm (17.7 in)
Max Machining Length	670 mm (26.4 in)
Bar Capacity	51 mm (2.0 in)
Main Chuck Size	6 in (A2-5 spindle nose)
Main Spindle Speed	5,000 RPM
Main Spindle Power	18.5 kW (25 hp)
Milling Spindle Speed	12,000 RPM
Milling Spindle Power	11 kW (15 hp)
Milling Spindle Taper	HSK-A40
B Axis Range	240 degrees (-30 to +210)
Y Axis Travel	100 mm (3.94 in)
Second Spindle	Yes (sub-spindle for back-working)
Tool Capacity	36 tools standard (72 optional)
Rapid Traverse Xz	50 m/min (1,969 ipm)
Machine Weight	7,500 kg (16,535 lb)
CNC Control	MAZATROL SmoothAi CNC

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

Strengths & Limitations

Strengths

Sub-spindle enables complete done-in-one processing of bar parts with both-ends features, eliminating secondary operations and re-fixturing that introduce positional errors
B-axis with 240-degree range and roller cam drive provides true 5-axis simultaneous milling capability in a compact machine envelope that most competing sub-spindle lathes lack
HSK-A40 milling spindle at 12,000 RPM handles precision contouring, helical milling, and form milling to true machining center standards on complex part features
51 mm bar capacity paired with both-ends machining makes the i-100S highly competitive for medical device and aerospace fastener production from bar stock

Limitations

51 mm bar capacity is smaller than the i-200 (65 mm) and i-300 (80 mm); shops regularly running bar stock above 50 mm need to step up to the i-200S
HSK-A40 milling spindle taper is smaller than HSK-A63 found on larger INTEGREX models, limiting maximum tool size and rigidity for larger milling tools
$280,000-$380,000 for a compact bar machine requires consistent high-value, complex part work to justify over a combination of dedicated turning and milling machines

Best For

Medical device manufacturers producing complex small implants, bone screws, and surgical instruments requiring turning, milling, and both-ends machining from bar stock Aerospace fastener and fitting manufacturers machining complex turned parts with milled features from both ends in one cycle without re-chucking High-precision job shops winning complex small-to-medium parts by offering done-in-one processing with tight inter-feature positional tolerances Watchmaking, optics, and precision instrument manufacturers needing 5-axis mill-turn capability in a compact footprint

Frequently Asked Questions

01 What is the difference between the INTEGREX i-100 and i-100S?

The i-100 has a single main spindle with a tailstock for supporting long parts during turning. The i-100S replaces the tailstock with a fully functional second turning spindle (sub-spindle) that can grip and machine the back face of the workpiece after the main spindle completes the front. The i-100S enables complete part processing in a single machine cycle, eliminating manual re-fixturing for back-face operations.

02 Can the i-100S machine parts longer than its 670 mm machining length?

No. The 670 mm maximum machining length is a hard constraint of the machine envelope. For longer shafts and turned parts, the i-200, i-300, or i-400 with tailstock configuration provides greater Z-axis travel. The i-100S is optimized for short-to-medium bar parts where both-ends machining and 5-axis milling are more important than extended length.

03 What CAM software works best with the INTEGREX i-100S?

The i-100S supports MAZATROL conversational programming for simpler parts and ISO G-code for complex 5-axis programs. For full 5-axis mill-turn work, shops typically use CAM software with Mazak-specific post processors: Esprit, Mastercam with INTEGREX post, NX with Mazak kinematics, or Hypermill. The sub-spindle adds programming complexity that requires a CAM environment capable of simulating both spindle positions simultaneously.

04 How does the i-100S compare to the DMG Mori NTX 1000?

Both are compact 5-axis mill-turn machines with sub-spindle capability. The DMG Mori NTX 1000 offers Siemens and Heidenhain control options and a slightly different spindle configuration. The i-100S offers MAZATROL conversational programming and Mazak's North American service infrastructure. Both are strong machines for small, complex parts; selection typically comes down to control preference and dealer support.

05 Is the i-100S suitable for titanium machining?

Yes, with appropriate tooling and programming. The 18.5 kW main turning spindle provides adequate torque for titanium turning at production feeds, and the 12,000 RPM milling spindle with HSK-A40 handles titanium milling with proper tool selection (carbide, positive rake, high-pressure coolant). The smaller HSK-A40 taper limits maximum milling tool diameter compared to larger INTEGREX models, so tool selection is more critical for titanium roughing operations.