Mazak VORTEX HORIZONTAL PROFILER 160 XP

$1,500,000 - $2,000,000 Updated 2026-03-19

Key Specifications

Table Size

4,000 x 1,600 mm (157.5 x 63.0 in)

Spindle Power

120 kW (161 hp) continuous

max table load

3,000 kg (6,614 lb)

max workpiece

4,000 x 1,600 x 500 mm (157.5 x 63.0 x 19.7 in)

spindle speed

30,000 RPM

spindle torque standard

42 Nm (31 ft-lb)

Overview

The Mazak VORTEX HORIZONTAL PROFILER 160 XP is the extreme-performance variant of Mazak's dedicated aerospace aluminum profiling platform, pushing spindle speed to 30,000 RPM and continuous power to 120 kW (161 hp) for maximum material removal rates on aluminum structural components. The XP designation stands for eXtreme Performance, and the numbers back it up — nearly three times the continuous power of the standard Profiler 160.

The machine features a 4,000 x 1,600 mm (157.5 x 63.0 in) table — wider than the standard 160 — with 3,000 kg (6,614 lb) load capacity. Maximum workpiece dimensions of 4,000 x 1,600 x 500 mm cover the largest single-piece aluminum structural parts in commercial and military aircraft programs, including full-size wing ribs and bulkheads.

The 30,000 RPM spindle delivers 120 kW (161 hp) continuous with a standard torque option at 42 Nm (31 ft-lb) and an optional high-torque configuration at 83 Nm (61 ft-lb). The high-torque option doubles the torque output while maintaining the same speed and power, enabling titanium fastener hole drilling and light titanium profiling alongside the primary aluminum work.

High-pressure through-spindle coolant runs 1.5 MPa (218 PSI) standard with options to 3.5 MPa (508 PSI) or 7.0 MPa (1,015 PSI). At 7 MPa, the coolant jet provides hydraulic chip breaking and evacuation during deep pocket machining where trapped chips would destroy surface finish at these cutting speeds.

The horizontal spindle orientation ensures natural chip fall-away from the cutting zone. The MAZATROL SmoothAi CNC optimizes cutting conditions in real time during long profiling passes. The 160 XP competes with dedicated high-speed profilers from Dufieux, Forest-Line, and Starrag, with Mazak differentiating on SmoothAi intelligence, global service network, and competitive lead times. Pricing runs $1,500,000 to $2,000,000.

Full Specifications

Parameter	Value
Table Size	4,000 x 1,600 mm (157.5 x 63.0 in)
Max Table Load	3,000 kg (6,614 lb)
Max Workpiece	4,000 x 1,600 x 500 mm (157.5 x 63.0 x 19.7 in)
Spindle Speed	30,000 RPM
Spindle Motor Power	120 kW (161 hp) continuous
Spindle Torque Standard	42 Nm (31 ft-lb)
Spindle Torque High Torque	83 Nm (61 ft-lb) optional
Coolant Pressure Standard	1.5 MPa (218 PSI)
Coolant Pressure Options	3.5 MPa (508 PSI) / 7.0 MPa (1,015 PSI)
Spindle Orientation	Horizontal
Construction	Horizontal spindle profiler
CNC Control	MAZATROL SmoothAi CNC

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

Strengths & Limitations

Strengths

30,000 RPM spindle at 120 kW continuous delivers the highest aluminum material removal rates in the Mazak lineup
83 Nm high-torque option enables titanium fastener hole drilling and light Ti profiling without a separate machine
Wider 4,000 x 1,600 mm table handles the largest wing ribs and structural panels in a single setup
7.0 MPa high-pressure coolant provides hydraulic chip breaking and evacuation during deep pocket machining
Horizontal spindle orientation prevents chip recutting that damages surface finish at extreme cutting speeds
SmoothAi CNC with real-time adaptive control optimizes conditions during long high-speed profiling passes
3,000 kg table load handles the heaviest aluminum billets and monolithic fixture setups

Limitations

Price exceeding $1.5M to $2M requires dedicated high-volume aerospace production to justify the investment
Purpose-built for aluminum high-speed profiling — not suitable as a general-purpose 5-axis machining center
Even the 83 Nm high-torque option limits titanium work to drilling and light profiling, not heavy roughing
Massive machine requires significant floor space, foundation engineering, high-capacity utilities, and specialized installation
Long lead times of 12-18 months for fully configured XP models

Best For

Tier-1 aerospace suppliers running high-volume aluminum wing rib, spar, and structural member production at maximum removal rates Aircraft OEMs and prime contractors producing fuselage frames, bulkheads, and floor beams from solid aluminum billets Defense aerospace manufacturers on military aircraft programs requiring maximum throughput on aluminum structural components Space launch vehicle manufacturers machining large aluminum structural rings, panels, and interstage components Dedicated aerospace profiling cells where the 160 XP runs multiple shifts on aluminum structural parts

Frequently Asked Questions

01 What does a VORTEX Horizontal Profiler 160 XP cost?

The 160 XP with 30K RPM / 120 kW spindle runs $1,500,000 to $2,000,000 depending on coolant pressure, ATC size, and automation options. This is a capital commitment for dedicated aerospace aluminum profiling at the highest performance level.

02 160 vs 160 XP?

The standard 160 runs 26K RPM at 45 kW continuous. The XP pushes to 30K RPM at 120 kW continuous — nearly 3x the power. The XP also gets a wider table (1,600 mm vs 1,250 mm). Choose XP only when maximum aluminum removal rates and the widest parts justify the price premium.

03 Why 120 kW continuous?

Aerospace aluminum profiling involves sustained high-power cutting for minutes at a time during long passes. Peak power ratings mean nothing here — the machine needs to maintain full power continuously. The 120 kW continuous rating ensures the spindle does not thermally derate during long profiling passes.

04 Can it replace a dedicated titanium machine?

No. The 83 Nm high-torque option handles titanium fastener holes and light finishing. For structural titanium machining, a VORTEX i-V or VARIAXIS i-800T with No.50 taper and 350+ Nm torque is required. The 160 XP is an aluminum-first machine.