Maximizing Versatility with Mazak Multi-Tasking

The INTEGREX i-500S AG HYBRID Multi-Tasking machine stands at the forefront of Mazak’s innovation. It offers unparalleled versatility and throughput when machining medium to large complex parts. This machine was engineered to combine the robust capabilities of a high-powered turning center with the comprehensive functions of a full-fledged machining. As a result, it excels in delivering finished parts in single setups, embodying the essence of Mazak’s Multi-Tasking 5-Axis CNC technology.

INTEGREX i-500S 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
Second 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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The INTEGREX i-500S AG Offers Unrivaled Precision and Efficiency in Gear Production

This machine features a secondary turning spindle (S) to ensure DONE IN ONE® machining. This feature streamlines the production process by minimizing the necessity for multiple setups. In addition, the integration of the HYBRID AUTO GEAR (AG) package encompasses the full spectrum of SMOOTH TECHNOLOGY solutions. This suite of gear manufacturing technology enables the machine to significantly cut down on lead times and enhance part accuracy. As a result, it’s a cornerstone of precision engineering with Mazak 5-Axis Multi-Tasking.


Advanced 5-Axis Capabilities for Complex Part Processing

With its advanced 5-axis capabilities, the INTEGREX i-500S AG effortlessly processes fully prismatic parts from solid blocks or castings—whether chucked or bar fed. This includes round parts or intricately sculptured aerospace components. The adaptability on this Mazak CNC machine enables it to create accurate and precise parts for demanding industries such as aerospace automotive, and contract manufacturing.


Highlighting INTEGREX i-500S AG’s Cutting-edge Features

This 5-axis machining center is designed to optimize efficiency and accuracy in machining operations. by incorporating the SMOOTH Gear Cutting software package, the INTEGREX i-500S AG offers comprehensive gear manufacturing solutions, including SMOOTH Gear Skiving, Hobbing, and Milling. As a result, it’s ideal for the production of external and internal spur, helical, and spline-type gears. In addition, the MX Hybrid Roller Guide System effectively dampens vibration to extend tool life and accommodate higher load capacities. These advanced features optimize workflows by reducing turnaround times, and elevating the overall output quality to position machine shops at the forefront of competitive manufacturing landscapes.


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