Maximizing Precision in Manufacturing with Mazak 

The INTEGREX i-500 AG HYBRID multi-tasking machine stands at the forefront of precision manufacturing. It offers unparalleled versatility and throughput for medium to large complex parts. This powerhouse uniquely merges the capabilities of a high-powered turning center with full-function machining to produce intricate components in single setups.

INTEGREX i-500 AG Features:

  • Process integration for high accuracy machining, reduction of in-process time and initial cost
  • Quickly and easily makes programs for cutting tool paths and measurement
  • Produces datum features, chamfers, edges and other part features in a single setup
  • SMOOTH Gear Cutting software package with SMOOTH Gear Skiving, SMOOTH Gear Hobbing and SMOOTH Gear Milling for producing external and internal spur, helical and spline-type gears
  • MX Hybrid Roller Guide System damps vibration to extend tool life and handle higher load capacities
  • Milling spindle provides a rotating B-axis range of 240 degrees
  • XX-tool magazine standard, with XXX-tool options available
  • Accommodates parts up to 27.56″ (700 mm) in diameter
Capacity Maximum Machining Diameter 700 mm
Maximum Machining Length 1529 mm
Main Spindle Maximum Speed 2500 rpm
Milling Spindle B-Axis Travel 240°
Maximum Speed 10000 rpm
Feed Axes Travel (X Axis) 845 mm
Travel (Y Axis) 430 mm
Travel (Z Axis) 1640 mm

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HYBRID AUTO GEAR (AG) Technology on the INTEGREX i-500 AG

The innovative HYBRID AUTO GEAR (AG) package is part of the SMOOTH TECHNOLOGY solutions comprehensive suite to ensure DONE IN ONE® gear production. This technology streamlines the manufacturing process from start to finish. In addition, the full 5-axis capabilities reduce lead times and enhance part accuracy by eliminating the need for multiple setups. Whether dealing with solid blocks, castings (chucked or bar fed), round parts, or intricately sculptured aerospace components, the INTEGREX i-500 AG processes them with ease and precision.


Advanced Gear Production Technologies

This Mazak 5-axis machine excels in producing external and internal spurs, helical, and spline-type gears with the SMOOTH Gear Cutting software package. This advanced gear manufacturing package includes technologies such as SMOOTH Gear Skiving, SMOOTH Gear Hobbing, and SMOOTH Gear Milling. The INTEGREX i-500 AG also features a MX Hybrid Roller Guide System, which damps vibration to extend tool life and accommodate higher load capacities. Additionally, the milling spindle’s rotating B-axis range of 240 degrees further underscores the machine’s precision and adaptability. This combination of advanced stability and versatile positioning ensures exceptional machining performance across a wide variety of materials and complex part geometries. The INTEGREX i-500 AG HYBRID machine embodies the pinnacle of integrated 5-axis technology by Mazak. With its advanced features and capabilities, it represents a significant leap forward for industries requiring highly precise and efficient machining solutions.


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