Frequently Asked Questions

Our focus is currently on solutions for businesses in the aerospace, aviation, industrial power, and oil & gas industries which have enormous catalogues of specialized parts. Production of these parts using conventional subtractive manufacturing techniques generally comes with very long lead times and high embedded cost structures relative to additive manufacturing (AM) solutions. Further, production of these high value parts using subtractive manufacturing techniques require the combination of many smaller parts into the final product.

Velo3D manufactures a unique end-to-end metal additive manufacturing solution that is sold to OEMs and Contract Manufactures who then produce parts. The parts are highly-complex with unique geometries not achievable through traditional manufacturing methods or conventional AM systems. These include but are not limited to:

• Impellers
• Heat Exchangers
• Specialized Valves
• Rocket Nozzles with Internal Cooling
• Static Mixers
• Turbines, and
• Combustors of all types

Our target customers include OEMs with vertically integrated operations as well as of contract manufacturers who are part of diverse supply chains.

The Velo3D end-to-end metal AM solution cuts lead time for traditionally manufactured parts by up to 75% without transportation delays, production line modification costs, supplier management and compliance costs, inventory, and warehousing costs, all while providing the production flexibility to instantly respond to customer and market demands.

Our solution provides the freedom to instantly choose where you need to produce/deliver a part. Simply upload the Velo3D “Golden Print File” to any Velo machine of like alloy. This one standard print file allows you to build that exact part on any Velo machine anywhere in the world—or any machine across the fleet in your own facility—without additional production line set up expense.

Yes, it is happening today. The Velo3D end-to-end metal AM Sapphire XC solution is built for exactly that purpose. It reduces part costs up to 60% and has the capacity for many parts. As traditional manufacturing evolves, metal AM printers will become integral to manufacturing floors because of the many advantages of the technology.

Companies have options to get the complex parts they need without design or quality compromise. Velo3D has built a global network of Contract Manufacturers that can produce parts as needed. The company also provides purchase options for our family of metal AM solutions enabling companies to start small and grow over time.

• Sapphire for development and low volumes
• Sapphire 1MZ for taller parts
• Sapphire XC for production volume scale
• Sapphire XC 1MZ for tall production scale 

Unlike other systems that are based on mesh-based workflows and thus require mesh import, Flow is designed with native CAD workflow in mind. Using imported CAD files provides for a better user experience and more control in the preparation of a build. It also prevents loss of the design intent that happens when CAD models are converted to meshes. Flow supports the import of the majority of native CAD formats, as well as Translation file formats such as .stp , iges, or .x_t.

Yes, Flow supports the output from many different commercially available lattice generation tools in file formats such as .3mf, .ltcx, .csv.

No. Leveraging our simulation capabilities requires that the file be a three-dimensional description of the part.

Flow supports users with the ability to generate and select regions of interest and apply supports where they see fit. Regions (saved selection sets) make the application of supports and application of sub-processes easy and organized. Flow features beam, wall, thin wall, and tree support types and recognizes as “support type” supports that were modeled in CAD.

Yes, Flow supports users with the ability to generate and select regions of interest and apply properties to those areas of interest.

Sapphire and Sapphire 1MZ Printers – Two 1kW Lasers

Sapphire XC and Sapphire XC 1MZ Printers – Eight 1kW Lasers

Sapphire and Sapphire1MZ – Total system footprint is 2.1m x 2.1m x 2.5m

Sapphire XC – Total system footprint is 8.53m x 3.35m x 4.25m

Sapphire XC 1MZ – Total system footprint is 8.53 x 5.00* x 4.75 m

*With build module in unpack position

No, both powder and filters and be changed without interrupting a build. The standard system holds enough for two builds.

IEC 62368 3D printers

IEC 60204 Safety of Machinery

IEC 60825-1 Laser Safety

Emissions Including (conducted and radiated Emissions):

FCC 47 CFR Part 15, Subpart B, ANSI C63.4 (2009) – USA

ICES-003 Issue 6 – Canada

AS/NZS CISPR 32 – Australia/New Zealand

VCCI-CSPIR 32 – Japan

EN 55032:2015 – EU

KN 32 South Korea: Electromagnetic compatibility – Emission requirements

Immunity Including: (for the EU)

KN 35 South Korea: Electromagnetic compatibility – Immunity requirements

EN 55035:2017 EU Multimedia Immunity standard

IEC61000-4-2 Electrostatic Discharge (ESD)

IEC61000-4-3 Radiated Frequency Immunity

IEC61000-4-4 Electrical Fast Transients Burst Immunity

IEC61000-4-5 Power Line Surge

IEC61000-4-6 RF Common Mode Immunity

IEC61000-4-8 Magnetic Fields (as applicable to the device or customer request)

IEC61000-4-11Voltage Dips and Interruptions

NFPA 484 chapter 13 for handling and transporting powder

Velo3D developed a unique non-contact recoater that does not wear or need regular replacement. However, like any other machine, we recommend regular preventive maintenance.

Yes, by keeping oxygen levels extremely low, powder reuse is significantly extended over conventional metal AM systems.

Velo3D has a unique ability to print low angles and overhangs down to zero degrees (horizontal), as well as large diameters and inner tubes up to 100mm without the need for supports. This not only significantly reduces or eliminates the need for post-processing, but it overcomes the “45-degree rule” – a conventional AM boundary requiring supports at angles less than 45 degrees. Velo3D frees designers to unlock a wealth of designs that can now be produced with additive technology.

Sapphire has an optional uninterruptible power supply (UPS) that can be purchased to enable it to ride through facility power fluctuations, and to gracefully shut down in the event of a major and sustained power outage.

The build is paused, and the operator is notified. Remote alerts (i.e., email) are supported.

Sapphire auto-generates an Assure report for each build, giving the operator a summary of the quality of the print layer by layer and the performance of the machine throughout the process.

It is possible to build inner diameters ranging from as large as 100mm all the way down to 500μm with Sapphire. If the geometry requires a larger inner diameter, the engineer can tilt the part by as little as a few degrees and expand that limit by more than two times. Similarly, once an engineer tilts the part, they can print features down to 300μm inner diameter holes.

The Velo Sapphire family of printers can print very thin walls, down to around 150μm. Importantly, even at this thickness, we can print to full z-height. This gives the printer the unprecedented ability to print aspect ratios of up to 6000:1

Depending upon the geometry, Sapphire can print parts with surface roughness below 5μm SA.

Some post-processing may be required based on customer requirements. This may include heat treating, polishing, machining, or the removal of a couple of supports. Velo3D solutions requires significantly fewer if any supports than conventional AM systems.

Generally, the answer is yes.

Velo3D uses a proprietary non-contact recoater designed to enable thinner walls, smaller inner diameter holes, lower angles, and higher aspect ratios.

Working in concert with Sapphire and Flow, Assure, a revolutionary quality monitoring and control system, provides visibility into every layer of the build through real-time, multi-sensor, physics-based excursion detection algorithms.

Assure provides unprecedented traceability of machine health, part integrity, and build reporting. It helps you understand if machine health is optimal before a build begins by monitoring optics, sensors, consumables, and powder bed quality, and displaying the data directly on the dashboard for all printers. Assure also predicts bulk material properties, in real-time, for each part through real-time, multi-sensor, physics-based excursion detection algorithms.

Assure automatically generates a detailed build report that can form the foundation of a Certificate of Compliance. This report offers full traceability of system performance and any predicted part defects during the build.

No. Assure is designed for and only works within the full Velo3D end-to-end solution.

Assure is not necessary to operate the Sapphire printer itself. However, Assure is essential to the high-quality output of the end-to-end metal AM solution, traceability, reporting, and compliance.

Assure has been optimized for Chrome and Safari. It may not display correctly with other browsers. However, if you are using a recent Microsoft Edge browser that is Chrome based will work as well. Assure uses JavaScript. If you have a JavaScript blocker, please disable it.

Our customers define the requirements for quality testing they need to validate their parts. Velo3D generally does not print production parts for customers. For Velo3D printed development or POC parts, we have full access to non-contact 3D scanning, destructive, and CT testing. For production parts (OEMs or CMs) these tests are performed or outsourced depending on in-house equipment.

Velo3D has a very sophisticated in-process inspection system including, but not limited to, using multiple sensors in the printer itself, a full topographical map of the part and powder bed on every layer using our height mapper system. We also obtain melt pool emission data from each laser which is used to identify potential process breakdowns.

Intelligent Fusion underpins the entire Velo3D end-to-end manufacturing solution by overseeing several core functions:  Geometry-Based Detection and Build Process Monitoring.

Intelligent Fusion is the key enabler for printing at low angles without the use of print supports. Specialized processes (recipes) were designed to minimize thermo-mechanical distortions and ensure high-quality surfaces at build angles as low as zero degrees.

Highly intelligent and sophisticated software uses geometric feature detection to apply the optimal physical processes to the appropriate features. To be able to do that, each geometric model is decomposed into various distinct geometric features and the appropriate optimal process is then applied automatically.

Additionally, the geometric feature detection algorithms use information from multiple layers, leveraging information from previous layers to define the print strategy for the next layer. The software can modify or adjusting parameters of the feedforward model and passing them on as instruction sets to the printer.

To achieve consistent material properties across a printed part and reduce print variability from build to build, the Velo3D system ensures that every relevant build parameter is monitored throughout the build process.

Natural process instabilities caused by minute hardware and powder variations as well as the uncertainties in the feed-forward simulation model can cause the process to drift outside the acceptable range, thereby affecting the final part outcome. Intelligent Fusion solves this problem by measuring in real time and using that as real-time data to adjust process parameters in-situ to ensure consistent outcomes.

To achieve consistent material properties across a printed part and reduce print variability from build to build, the Velo3D system ensures that every relevant build parameter is monitored throughout the build process.

Powder can be used virtually indefinately then returned to the powder hopper. Unused powder is vacuumed up and sieved to remove clumps or welding slag. Powder remains in an inert environment as long as you are careful to vacuum up all the powder when the build is done and before opening the chamber.

Our dedicated applications engineers are there for you through every step of the AM process, shepherding the design, development, POC, and manufacturing phases to ensure the best project outcomes. In many ways, we become an extension of your existing team.

Velo3D is a global company with offices and representation in North America, Asia, and Europe.

Simply click on “Speak with an Engineer” at the top of any page on this site, complete our contact form, and one of our experts will reach out promptly to answer any questions and discuss specific products or applications with you.

Velo3D has an extensive Service Agreement that includes PM, Repair Parts, Select Upgrades, Product Support, and Software licenses. Product Support under our standard service Level agreement includes Access to Customer Support Portal: Software, documentation, ticketing, product notices, service history, knowledgebase, file transfer (SFTP). Assigned Customer Success Agent: Weekly meetings and customer support responses. Applications Support: Training, part reviews, and slicing support. Engineering Support: Quarterly priorities alignment, advanced troubleshooting as required.