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Intelligent Laser Technology
The Mazak Optonics Underground
Factory is the first Eco-Factory built below ground for the
manufacture of machine tools. The 293,000 square foot facility
is located in Minokamo, Japan and is one of the facilities
dedicated to the production of Mazak laser-cutting machines.
One of the bays at Mazak Optonics’ award
winning underground laser production facility.
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The global strength of Mazak
YAMAZAKI MAZAK
TABLE OF CONTENTS
Yamazaki Mazak is the world’s largest manufacturer of machine tools. We produce
systems for the precision manufacturing of metal parts including laser-cutting machines,
CNC turning centers, horizontal and vertical machining centers, multi-tasking machining
centers, turnkey cells and software solutions to help customers achieve lean, efficient
manufacturing operations. We have developed unique products that realize unsurpassed
productivity and established 79 Technology and Technical Centers all over the world to
provide total solutions and optimum service support close to our customers.
TOPICS
Intelligent Technology
2D Fiber Machines
2D CO2 Machines
MAZAK OPTONICS LASER TECHNOLOGY
Mazak Optonics offers an extensive range of 2D and 3D laser-cutting equipment
encompassing over 50 machine models. This innovative range of products enables
Mazak to better meet your specific laser application needs. Mazak is a laser technology
leader who can significantly improve production efficiency, competitive positioning and
profitability. We utilize innovative engineering and intelligent automation to simplify
operation and deliver more consistent machine performance. Mazak Optonics supports
our large North American installation base from our North American headquarters in
Elgin, IL.
Yamazaki Mazak Minokamo 1 Plant in
Gifu-Prefecture, Japan.
Mazak Corporation’s Headquarters for the
Americas, Manufacturing Plant and Technology
Center in Florence, KY.
2D/3D Plate & Pipe
Automation Systems
Intelligent Factory
Mazak Optonics Corporation’s North American
support facility in Elgin, IL is the largest
dedicated laser technology center in the world.
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The Elgin Laser Technology Center is a key
focal point for laser symposiums, training and
application development.
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Mazak Optonics utilizes
intelligent technology to
engineer laser-cutting
machines that deliver
innovation, performance,
automation & value.
Mazak has engineered exclusive Intelligent Multi-Function Torch
technology that improves reliability, achieves high performance
and enables advanced Intelligent Functions not available on
many competitive models.
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Mazak Intelligent Technology
INTELLIGENT FUNCTIONS IMPROVE EASE OF OPERATION & MACHINE EFFICIENCY
Mazak has developed a series of Intelligent Functions designed to automate machine setup and monitor the cutting performance. These Intelligent Functions can dramatically
simplify operations and automatically adjust cutting parameters to increase the quality of parts and overall throughput.
Intelligent Setup Functions
Intelligent Monitoring Functions
A wide variety of Functions are available for ease of operation and reduced setup time.
The torch has sensors that monitor piercing and cutting operations to improve
throughput and part quality. If an anomaly is detected, the operation is adjusted or
paused to automatically achieve effective cutting conditions.
Automatic Torch Changing
Automatic Nozzle Changing
Automatic Focus Positioning
Focus Detection
Beam Diameter Control
Pierce Detection
Plasma Detection
Burn Detection
Lens Monitoring
Automatic Profiler Calibration
Automatic Nozzle Cleaning
Automatic Torch Changing elimiates the need
to have the operator manually change the
lenses as needed for applications.
Automatic Nozzle Changing helps reduce
operator errors, improves consistency of
operation and lowers operator dependency.
Pierce Detection senses when the pierce
breaks through the material as compared to a
programmed pierce that would include added
time to account for variations in the process.
Auto Focus Positioning eliminates the need to
have the operator measure, adjust, and set the
focal distance by automating the process.
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Fiber laser technology offers specific performance that
increases both throughput and lowers cost of operation. With
fiber’s improved cutting speed, it offers the ability to cut a wide
range of materials. This speed is particularly benefitical when
cutting stainless steel and aluminum, but also a wide range of
mild steel.
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Fiber Technology
OPTIPLEX 3015/4020 FIBER
OPTIPLEX NEXUS 3015 FIBER
OPTIPLEX Fiber series utilizes a flying optics, 2 pallet changer design with a helical rack
and pinion positioning system that features high cutting speeds, maximum throughput
and rugged construction. It incorporates Intelligent Multi-Function Torch and Nozzle
Changer technology to directly increase the productivity of the end user by allowing
the machine to optimize the torch setup automatically per program. This optimization
can dramatically improve cut speeds, increase throughput and require less operator
intervention, delivering more predictable processing day after day.
The OPTIPLEX NEXUS Fiber is a 2D flying optics laser-cutting system that utilizes rugged
construction and an innovative design to deliver high performance for fabrication
job shops and production environments. The durable 28,330 pound NEXUS Fiber
incorporates a helical rack and pinion positioning system that features solid throughput
and high accuracy. It has been engineered to be utilized with Mazak’s extensive range of
automated material handling systems.
Intelligent performance for maximum productivity
Cutting-edge technology with an economical investment
OPTIPLEX 3015 Fiber
Table Size
Generator
Watts
Mild Steel
Thickness
Stainless Steel
Aluminum
Positioning System
Positioning Accuracy
Rapid Feed / Simultaneous
Acceleration
CNC
Auto Torch Changing
Auto Nozzle Changing
Beam Diameter Control
Intelligent Setup Auto Focus Positioning
Auto Profiler Calibration
Auto Nozzle Cleaning
Focus Detection
Pierce Detection
Plasma Detection
Intelligent
Monitoring
Burn Detection
Lens Monitoring
60” x 120”
IPG
2.0 kW
0.500”
0.380”
0.320”
Helical rack and pinion
+0.002”/19.7”
4,724 ipm / 6,680 imp
1.2 G
Preview 3
OPTIPLEX Fiber series machines
deliver maximum performance and
superior throughput.
OPTIPLEX 4020 Fiber
78” x 157”
4.0 kW
1.000”
0.750”
0.630”
2.0 kW
0.500”
0.380”
0.320”
OPTIPLEX NEXUS 3015 Fiber
60” x 120”
4.0 kW
0.100”
0.750”
0.630”
2.0 kW
0.500”
0.380”
0.320”
3.0 kW
0.750”
0.500”
0.500”
4.0 kW
1.000”
0.750”
0.630”
2,362 ipm / 3,340 imp
0.6 G
OPTIPLEX NEXUS Fiber offers
both high technology and
incredible value.
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CO2 series machines deliver superior
performance when cutting thicker mild
steel. They achieve excellent finishes, faster
cutting speeds and lower cost of operation
for appropriate applications as compared to
fiber technology cutting with nitrogen. Recent
developments in resonator and beam delivery
systems have significantly reduced the cost of
operation.
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CO2 Technology
OPTIPLEX 3015/4020 CO2
SUPER TURBO-X 1212 CO2
The OPTIPLEX CO2 offers unique flexible performance features that specifically meet the
needs of high variation job shops including Intelligent Setup and Monitoring Funtions.
The SUPER TURBO-X 44 offers a unique 4’ x 4’ table design for easy accessibility and
proven performance.
OPTIPLEX NEXUS 3015 CO2
SUPER TURBO-X 3015 CO2
The OPTIPLEX NEXUS CO2 offers unique performance features in a flexible design that is
available in a single fixed pallet, manual pallet or automated two pallet design.
The SUPER TURBO-X is built on the industry’s most reliable laser platform. It features a
rugged hybrid design. Also available in 2412 and 4020 configurations.
Flexible job shop laser-cutting system
Compact dynamo for when floor space is limited
Simply Innovative - Intelligent Functions and a tremendous value
OPTIPLEX 3015
Table Size
Resonator
Watts
Mild Steel
Thickness
Stainless Steel
Aluminum
Positioning System
Positioning Accuracy
Rapid Feed / Simultaneous
Acceleration
CNC
Auto Torch Changing
Auto Nozzle Changing
Beam Diameter Control
Intelligent Setup Auto Focus Positioning
Auto Profiler Calibration
Auto Nozzle Cleaning
Focus Detection
Pierce Detection
Plasma Detection
Intelligent
Monitoring
Burn Detection
Lens Monitoring
OPTIPLEX 4020
delivers thin to
thick flexibility.
60” x 120”
New Type 10 with ECO Mode
2.5 kW
4.0 kW
6.0 kW
0.750”
1.000”
1.000”
0.375”
0.500”
0.590”
0.250”
0.375”
0.472”
Helical rack and pinion
+0.002”/19.7”
4,724 ipm / 6,680 imp
1.2 G
Preview 3
Rugged hybrid design now featuring the new Preview 3 control
OPTIPLEX 4020
78” x 157”
2.5 kW
0.750”
0.375”
0.250”
4.0 kW
1.000”
0.500”
0.375”
6.0 kW
1.000”
0.590”
0.472”
OPTIPLEX NEXUS 3015
SUPER TURBO-X 1212
SUPER TURBO-X 3015
60” x 120”
48” x 48”
60” x 120”
2.5 kW
0.750”
0.375”
0.250”
2.5 kW
4.0kW
0.750”
1.000”
0.315”
0.500”
0.236”
0.375”
Ball Screw
+0.0004”/19.69”
1,969 ipm / 2,784 imp
0.4 G
2.5 kW
0.750”
0.315”
0.236”
2,362 ipm / 3,340 ipm
0.8 G
OPTIPLEX NEXUS 3015
offers affordability.
SUPER TURBO-X 1212 is
designed for compact performance.
4.0 kW
1.000”
0.500”
0.375”
SUPER TURBO-X 3015 for
thicker applications.
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FABRI GEAR series tube-cutting machines deliver a wide
range of benefits for fabricators. Their multi-axis capabilities
enable you to cut a much wider range of structural material not
possible on 2D configurations. FABRI GEAR utilizes a unique
four chuck material handling system and robust structural
design to support these often longer and heavier applications.
This type of rigid design also improves machine precision for all
types of workpieces.
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Multi-Axis Technology
FABRI GEAR 220/400 2D/3D
Rugged 3D precision for tube and structural applications
The 3D FABRI GEAR cuts a wide variety of tubes including round, square, rectangular
and triangular. It can also process I and H beams, C-channel, angle iron and additional
user-defined shapes. Featuring a powerful, high-precision 6-axis laser, the 3D FABRI
GEAR can handle larger, longer, thicker and heavier material than similar machines due
to its rigid workpiece handling system incorporating a four chuck design.
SPACE GEAR U-44 2D/3D
Cut flat, tube, stamped, hydroformed and spun pre-formed parts
The SPACE GEAR-U44 is a compact and affordable all-in-one 2D/3D laser center for
maximum flexibility. Use its triple-mode, 6-axis capabilities to expand your shop’s
horizons and raise yourself above the competition.
SPACE GEAR 510 MKII 2D/3D
Ultimate 2D/3D job shop flexibility
Mazak’s SPACE GEAR 510 MkII delivers full size machine performance with the flexibility
of 2D/3D features. Tubes, pipes, and structural shapes can all be processed by adding a
CNC rotary chuck and supports for long workpieces. In all, six axes of CNC control allow
you to cut weld preps, angled features, and much more in a single setup.
FABRI GEAR 220
Standard diameter
Material Weight
Material Length
Resonator
Watts
Mild Steel
Stainless Steel
Aluminum
Positioning System
Positioning Accuracy
CNC
Thickness
SPACE GEAR U-44
Table Size
Resonator
Watts
Mild Steel
Thickness
Stainless Steel
Aluminum
Positioning System
Positioning Accuracy
Rapid Feed
Acceleration
CNC
FABRI GEAR 400
8.66” round/ 6” square
16.0” round/ 11.8” square
728 lbs.
1058 lbs.
6 M - 236”, 8 M - 315”, 12 M - 472”, 15 M - 590”
Type 10 with ECO Mode
2.5 kW
4.0 kW
2.5 kW
4.0 kW
0.750”
0.875”
0.750”
0.875”
0.312”
0.375”
0.312”
0.375”
0.250”
0.375”
0.250”
0.375”
Rack & pinion, ball screw
Y/Z +0.0004”/19.7” X/U/V +0.0020”/19.7”
Mazak FX
SPACE GEAR 510 MKII
48” x 48”
60” x 120”
New Type 10 with ECO Mode
2.5 kW
4.0 kW
2.5 kW
0.750”
0.875”
0.750”
0.312”
0.375”
0.312”
0.250”
0.375”
0.250”
Ball Screw
+0.004”/19.7”
945 ipm
0.3 G
Mazak FX
SPACE GEAR U-44 features a 4’x4’
table and the ability to add a chuck for
tube processing.
4.0 kW
0.875”
0.375”
0.375”
SPACE GEAR 510 MKII is a larger
format hybrid design for increased
capabilities.
FABRI GEAR series machines
laser cuts mill-length pipe and
structural material.
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Over 700 Mazak laser-cutting machines are in automation
systems that are currently reducing operating costs for
their owners in North America. The below system is a three
machine cell utilized at Mazak Corporations Florence Kentucky
manufacturing center. It is a linear automation system with
ten pallet material storage tower. The production cell is a
cornerstone for the manufacture of sheet metal panels for
Mazak machine tools.
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Mazak Advanced Automation
MATERIAL AUTOMATION SYSTEMS WILL
EXTEND THE THROUGHPUT CAPACITY OF
YOUR MACHINES
Mazak was the first manufacturer to introduce laser cutting machines into a Flexible
Manufacturing System. Today we offer the following systems:
The benefits that result from a company implementing laser automation are profound.
A typical standalone laser is utilized only a fraction of the usable workweek. It sits
idle while waiting for setup or material, as well as during lunch breaks and off hours.
Owners who track actual laser cut time are almost always shocked to see the reality of
the underutilization of such a major asset.
 Vertical flexible manufacturing
Automation systems provide the ability to flex capacity through lights-out operation,
without the burden of adding manpower. It also makes one-piece flow more practical,
while producing short-run efficiencies that will reduce non value-added fabricating time.
The bottom line is typically up to a 50% increase in capacity as compared to standalone
machines and a significant reduction in lead times.
COMPACT LOAD/UNLOAD SYSTEM
The above image illustrates a Vertical Compact Load/Unload
System. It takes up very little additional floorspace and is
typically utilized in operations with fewer material changes such
as batch production.
 Compact load/unload
 Automated part sorting
 Automated storage/retrieval
AUTOMATION PRODUCTIVITY
1. Standalone Shuttle Table 52%
2. Load/Unload System 75%
Beam
On-Time
3. Flexible Manufacturing System 92%
COMPACT VERTICAL FMS
Veritcal Flexible Manufacturing Systems also are also compact
in design and deliver the flexibility to automate many material
types/thicknesses. Designs are modular, enabling the addition
of multiple storage towers and unload configurations, but are
dedicated to a single machine system.
LINEAR FMS
Linear Systems deliver all of the modularity and flexibility of
vertical systems, but enable inclusion of multiple machines
within a single system. Mazak Linear Automation Systems can
integrate both CO2 and Fiber laser-cutting machines into a
single FMS as illustrated above.
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Intelligent Factory
helps manage
real-time machine,
shop and factory
performance.
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Mazak Intelligent Factory
TAKE RAW DATA, READ AND ANALYZE IT,
THEN TURN IT INTO MORE ACTIONABLE
INFORMATION
Intelligent Factory utilizing Merlin enables you to visualize the performance of cells,
departments and the plant overall as compared to historical or target performance.
These insights are the real-time tools that can enable fabricators to manage the process
rather than reacting to historical reporting.
 Managers can see the productivity and increased profitability as it happens in realtime
 Productivity problems can be identified fast - accelerating resolution
 Plant-wide productivity increases in the range of 10% to 50%
 Dashboard metrics can be available for everyone on the shop floor to see
Merlin is an industrial internet platform solution for manufacturing including hardware
and software machine monitoring solutions that connects directly to manufacturing
equipment. Merlin is designed to monitor every machine in your shop, CNC machines,
non-CNC machines, fabrication centers and manual processes, all tied together in a
production process manufacturing execution system.
Above is an example of one of the many screen page configurations that can be generated by
Merlin. It displays a dashboard of overall metrics or KPIs as compared to targets including Overall
Equipment Effectiveness (OEE). OEE is a statistical measurement (OEE = Availability x Quality x
Performance) used to determine how efficient a machine is running. It helps the user identify
problems fast, before production or quality suffers, with real-time monitoring. It measures the
machines’ actual run time, the quantity of parts produced, the quality metric, and the actual rate
of production. Metrics colored green indicated good results, yellow indicates underperformance
and red is used for machines that are not operating.
Machine monitoring delivers instantaneous, automatic and timed pro-active email and
text alerts to minimize downtime. Detailed analyses of downtime root causes points
to areas requiring more operators training. Identification and removal of unnecessary
optional stops helps recover lost production time.
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Mazak Optonics Corporation
2725 Galvin Court
Elgin, Illinois 60124
847.252.4500
www.mazakoptonics.com
Specifications subject to change without
notice. Actual cutting performance is based
on various parameters including type and
quality of material, assist gas and cutting
speed.
11.2015