The Mazak INTEGREX i-250H S AG is an advanced hybrid multi-tasking CNC machine that combines turning, full 5-axis milling, and integrated gear cutting in a single setup. Built on the i-250H S platform, it includes a second spindle (“S”) for simultaneous machining and part transfer, while the “AG” (Auto Gear) configuration adds gear skiving, hobbing, and milling capabilities. This allows manufacturers to complete highly complex components—including gear features—without transferring parts between machines, significantly improving accuracy and efficiency.
The machine typically handles workpieces up to approximately 670 mm in diameter with machining lengths around 1,000–1,500 mm. It features dual 8-inch spindles with speeds up to 5,000 rpm and a high-speed milling spindle reaching around 12,000 rpm. A B-axis milling head enables complex angular machining, while the hybrid roller guide system enhances rigidity and vibration damping for stable cutting. Integrated gear software allows production of spur, helical, and spline gears within the same setup.
Equipped with MAZATROL Smooth or SmoothAi control, the i-250H S AG supports conversational programming, automation integration, and in-process measurement. It is widely used in aerospace, automotive, and precision gear manufacturing industries requiring high accuracy and process consolidation.
MAZAK INTEGREX I-250H S AGSPECIFICATIONS
MAZAK INTEGREX I-250H S AG – AXIS
Advanced multi-tasking CNC machine with gear cutting capability
X, Y, Z linear axes
B-axis tilting milling spindle
C-axis for main and sub-spindle indexing
Dual spindle (S variant) for complete part machining
Full simultaneous 5-axis machining with AG gear cutting (skiving, hobbing)
MAZAK INTEGREX I-250H S AG – AXIS TRAVELS
X-axis travel: approx. 695 mm
Y-axis travel: approx. 300 mm
Z-axis travel: approx. 1100–1500 mm
B-axis rotation: approx. -30° to +190°
C-axis rotation: 360° continuous (main & sub spindle)
MAZAK INTEGREX I-250H S AG – CAPACITY
Maximum turning diameter: approx. 670 mm
Maximum machining length: approx. 1000–1500 mm
Chuck size: 8 inch
Sub-spindle enables full front and back machining
Suitable for medium-sized precision and gear components
MAZAK INTEGREX I-250H S AG – SPINDLE
Main spindle speed: up to approx. 4000–5000 RPM
Sub-spindle speed: up to approx. 4000–5000 RPM
Milling spindle speed: up to 12000 RPM
High-torque built-in motor spindle
Synchronized spindle control for gear cutting
MAZAK INTEGREX I-250H S AG – TABLE
Main and sub-spindles act as workholding units
High rigidity structure for precision machining
Designed for simultaneous front and back operations
Optimized for multi-face and gear machining
MAZAK INTEGREX I-250H S AG – TOOL TURRET
Tool magazine capacity: approx. 30–72 tools
Automatic tool changer (ATC)
Supports gear cutting tools and probing systems
Capable of handling complex multi-operation setups
MAZAK INTEGREX I-250H S AG – FEEDRATES
High-speed rapid traverse
Smooth and precise axis control
Optimized for gear cutting and multi-tasking
Stable machining under continuous operation
MAZAK INTEGREX I-250H S AG – COOLANT & CHIP MANAGEMENT
High-pressure coolant system
Through-spindle coolant capability
Smooth Coolant system for efficiency
Chip conveyor system for continuous operation
MAZAK INTEGREX I-250H S AG – CONTROL SYSTEM
Mazatrol SmoothAi CNC control
Conversational programming with gear cutting support
AI-based machining optimization
Digital twin and simulation capabilities
MAZAK INTEGREX I-250H S AG – POWER & AIR REQUIREMENTS
Power requirement: approx. 45–65 kVA
Air pressure requirement: approx. 5–6 bar
Energy-efficient system with monitoring
Designed for industrial continuous machining
MAZAK INTEGREX I-250H S AG – DIMENSIONS
Machine footprint: approx. 3600 x 2400 mm
Machine height: approx. 2600 mm
Machine weight: approx. 11,000–14,000 kg
Rigid and compact machine structure
MAZAK INTEGREX I-250H S AG – GENERAL INFORMATION
Combines turning, milling, 5-axis machining, and gear cutting
Dual spindle enables complete part machining in one setup
Eliminates need for separate gear cutting machines
Improves accuracy and reduces cycle time
Designed for high-mix, high-precision production
INDUSTRIES THAT USE MAZAK INTEGREX I-250H S AG
Automotive (gear and transmission manufacturing)
Aerospace industry
Industrial machinery
Energy and power transmission
Precision engineering
TYPICAL PARTS MAZAK INTEGREX I-250H S AG CAN PRODUCE
Gears (spur, helical, internal)
Transmission shafts with gear profiles
Aerospace precision components
Pump and valve components
Complex multi-operation parts
WHY CHOOSE MAZAK INTEGREX I-250H S AG
Combines gear cutting and full multi-tasking machining
Dual spindle for complete part finishing
Reduces setups and improves productivity
High accuracy with integrated inspection capability
Ideal for complex, high-value manufacturing
WHY BUY USED MAZAK INTEGREX I-250H S AG
Purchasing a used Mazak INTEGREX i-250H S AG provides access to a highly capable multi-tasking and gear-cutting machine at a significantly lower cost than buying new. The combination of dual spindles and integrated gear machining allows complete part production—including gear profiles—in a single setup. This reduces cycle times, minimizes handling, and improves overall part accuracy, making it ideal for manufacturers producing shafts, transmission components, and complex precision parts.
Used machines from 2010 to 2025 typically include MAZATROL Smooth or SmoothAi controls, offering improved programming efficiency, better diagnostics, and compatibility with automation systems. These machines are suitable for both high-mix, low-volume production and batch manufacturing. Machines from 2000–2010 may not always include full AG functionality in earlier configurations but still provide strong mechanical performance with older control systems.
Cutting time is one of the most important factors when evaluating a used unit. Machines with lower spindle and gear-cutting hours generally have less wear on key components such as spindle bearings, B-axis heads, and synchronization systems used for gear machining. Maintenance history, tooling packages, and included gear software significantly influence value. Buying used allows manufacturers to adopt advanced hybrid gear-integrated machining technology while managing capital costs and reducing depreciation.
HOW MUCH DOES A USED MAZAK INTEGREX I-250H S AGCOST?
The cost of a used Mazak INTEGREX i-250H S AG varies depending on age, condition, configuration, and total cutting hours. Machines manufactured between 2010 and 2025 typically range from approximately $220,000 to $450,000. Units at the higher end of this range often include full AG gear-cutting packages, low spindle hours, modern MAZATROL Smooth or SmoothAi controls, and additional features such as automation interfaces or tool packages. These factors increase productivity and extend machine life, justifying higher pricing.
Machines from the 2000–2010 period are generally priced between $120,000 and $250,000, depending on condition and upgrades. Some may not include the latest gear-cutting software or may require retrofits to support advanced AG functionality, but they still provide strong multi-tasking capability for complex parts.
Pre-2000 machines in this exact configuration are generally not available, as integrated AG gear-cutting technology is part of a newer generation of INTEGREX machines. Cutting hours play a major role in valuation; machines with high spindle and gear machining usage may require refurbishment of key components, reducing their price. Buyers should also consider included tooling, gear software packages, automation readiness, and service history, as these factors significantly impact total investment and long-term return.
