Mazak INTEGREX i-500S

$550,000 - $800,000 Updated 2026-03-19

Key Specifications

X Travel

845 mm (33.27 in)

Y Travel

430 mm (16.93 in)

Tool Capacity

36 tools (72 or 110 optional)

max machining diameter

Φ27.56″

max machining length

61.97″ /102.13″

b axis range

240° (-30° to +210°)

Overview

The Mazak INTEGREX i-500S adds a programmable sub spindle to the large-capacity i-500 platform, enabling done-in-one processing of both ends on workpieces up to 700 mm (27.56 in) in diameter and up to 3,075 mm (121.02 in) in length. This is one of the few multi-tasking machines capable of automatic part transfer at this scale, making it uniquely suited for large aerospace shafts, energy components, and heavy industrial parts.

The main turning spindle handles workpieces up to 700 mm diameter on a 10-inch chuck, with speeds from 2,000 to 4,000 RPM depending on bore configuration. The sub spindle provides 22 kW (30 hp) at 4,000 RPM for back-working and part transfer. Milling spindle options include 12,000 RPM standard, 12,000 RPM high-output, 20,000 RPM high-speed, and No. 50 taper at 10,000 RPM.

The 430 mm (16.93 in) Y-axis travel is 72% more than the i-400S. X-axis extends 845 mm (33.27 in). The B-axis provides 240 degrees with 0.0001-degree resolution through a roller gear cam drive. C-axis features full-circumference disc brake for heavy milling rigidity.

Available in multiple bed lengths up to 3,075 mm machining length. Machine weight exceeds 26,000 kg. New machines $550,000-$800,000. Competitors include the DMG Mori CTX gamma 2000 TC and Okuma Multus U5000.

Full Specifications

Parameter	Value
Max Machining Diameter	Φ27.56″
Max Machining Length	61.97″ /102.13″
X-Axis Travel	845 mm (33.27 in)
Y-Axis Travel	430 mm (16.93 in)
B Axis Range	240° (-30° to +210°)
B Axis Resolution	0.0001°
C Axis Rotation	360° continuous with disc brake (both spindles)
Main Spindle Speed	2,000-4,000 RPM (varies by bore)
Sub Spindle Speed	4,000 RPM
Sub Spindle Power	22 kW (30 hp)
Milling Spindle Speed	12,000 RPM std / 20,000 RPM HS / 10,000 RPM No. 50
Milling Spindle Taper	HSK-A63 or No. 50
Chuck Size	10″
Tool Capacity	36 tools (72 or 110 optional)
Rapid Traverse Xz	50 m/min (1,969 ipm)
Machine Weight	26,000+ kg (57,320+ lb)
CNC Control	MAZATROL SmoothAi CNC

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

Strengths & Limitations

Strengths

Done-in-one capability at 700 mm diameter and 121 inches length is rare in any multi-tasking machine
430 mm Y-axis is 72% more than i-400S for complex off-center milling on very large workpieces
Four milling spindle options adapt to different material mixes without changing the machine
Sub spindle enables automatic part transfer on large workpieces most competitors cannot match
Multiple bed lengths up to 10 feet handle the longest shaft-type components
B-axis roller gear cam with disc brake C-axis provides rigidity for heavy milling at scale

Limitations

$550K-$800K investment requires consistent large-part high-value production
26,000+ kg demands engineered foundations and specialized rigging
Lower main spindle speeds (2,000-4,000 RPM) limit small-diameter turning productivity
Programming dual-spindle operations on large expensive parts requires extreme care and verification
Lead times often run 9-18 months for custom configurations

Best For

Aerospace manufacturers machining large landing gear, engine shafts, and structural members requiring both-end 5-axis processing Power generation producing large turbine shafts and generator components up to 10 feet long Oil and gas with very large workpieces needing complete multi-axis machining Defense contractors producing large ordnance and naval hardware with both-end features Heavy industrial manufacturers running large-format components in specialty alloys

Frequently Asked Questions

01 i-500S cost?

Base starts around $550,000. Loaded with No. 50 milling, expanded magazine, and long bed runs $700K-$800K.

02 i-500S vs i-500?

The S adds a sub spindle for automatic part transfer and back-working. Adds $100K-$150K but eliminates a second operation on parts with both-end features.

03 i-500S vs i-500ST?

The ST additionally adds a lower turret for simultaneous cutting. ST adds another $100K-$150K over the S but delivers 30-50% cycle time reduction on complex parts.

04 Which milling spindle?

12K high-output for mixed materials, 20K for aluminum aerospace, No. 50 for maximum rigidity on steel and titanium. Most mixed-material shops choose 12K high-output.