An End-to-End Manufacturing Solution Unlike Any Other
Velo3D has developed an end-to-end manufacturing solution comprised of software, hardware, and an intelligent underlying manufacturing process that allows engineers to build mission-critical parts.
Fully-Integrated Software and Hardware Solution for Unprecedented, Production-Ready Results
Flow™ is the only print preparation software that delivers a print outcome based on the designer’s intent with little or no DfAM. Flow™ lets you print parts that were previously impossible with conventional AM technologies.
Import Native CAD Files
Native CAD workflow eliminates the need for translation to labor intensive STL mesh file formats that require healing and fixing for AM.
Process aware simulation in Flow can correct for build deformation and post-processing issues before the build even begins, leading to high first print success rates that exceed industry standards.
Flow™ has a sophisticated composer that detects geometric features and applies an optimized process to those features, delivering predictable print outcomes. Unlike other slicing software, geometric feature detection uses information from previous layers to define print strategy for the next layer.
Import Native CAD Files
State-of-the-Art 3D Metal Printers
Our next-generation Velo3D Sapphire® family of printers all use the same software, run the same process, and use the same materials ensuring repeatable consistency across the fleet. Engineered to meet your design, performance, and quality requirements, our printers continually monitor and control the build layer-by-layer for predicable and efficient production. The outcome results in complex part geometries for real-world applications.
Unlike conventional AM printers, the Sapphire® printers utilize a proprietary protrusion tolerant non-contact recoater that almost eliminates the risk of part collisions, dramatically improving yields and facilitating a printing process enabling lower angles and overhangs down to zero degrees, thin leak tight walls, large diameter and extremely small inner tubes, with little or no supports.
Laser and Optics Fidelity
Run-time and one-click optics calibrations
Self-cleaning laser windows
Powder Bed Uniformity
Per-layer 3D powder bed height mapping
Full-height printing without interruption for powder addition or filter changes
Sub-10 ppm O2 during normal operation
Active humidity monitoring
Ambient temperature and pressure operation
Highly regulated chamber gas flows
High efficiency spatter removal
Low Volume & Development
315mm Ø x 400mm z
Sapphire® 1MZ Printer
315mm Ø x 1000mm z
Sapphire® XC Printer
Large Volume, Production Scale
600mm Ø x 550mm z
Quality assurance is essential, and it’s never been easier.
In real time, Assure™ software provides instant visibility into every layer of the build through real-time sensors, physics-based excursion detection algorithms, and optical measurements. These in-situ monitoring systems and reports give engineers confidence that the printer is operating at optimal performance and the resulting part is of the highest quality. Assure™ also provides a detailed build report showing each layer. This quality control system accelerates the move to production by verifying part-to-part consistency to enable scalability.
Assure™ tracks and reports the Sapphire® pre flight check prior to each build. Together, these checks validate that the Sapphire® printers are ready to print and that they stay within specification during a build.
Each build includes a detailed build report that contains part quality data and printer health results, making it easier to qualify parts to move AM into production.
Underlying Manufacturing Process
Intelligent Fusion® is the catalyst to the unique printing capabilities of the end-to-end solution. Specialized processes (recipes) were designed to minimize thermo-mechanical distortions and ensure high-quality surfaces at build angles as low as zero degrees. It is built into all Sapphire® printers.
Intelligent Fusion® is the key enabler for printing lower angles, thinner walls, and high aspect ratios. This process control is so precise, the need to design-in support structures is greatly reduced and often eliminated.
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.
Monitoring the Build Process
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 can cause the process to drift outside the acceptable range, thereby affecting the final part outcome. 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.
Monitoring the Build Process
The Sapphire® family of printers are capable of printing a variety of metals depending on the need and use case. This flexibility gives engineers more options and configurations to achieve their goals.
Foundry-grade beryllium free aluminum-silicon alloy. It has excellent weldability and is heat treatable to T5, T6 and T7. This alloy is a lightweight, corrosion resistant, and highly dynamic load-bearing material.
Amerprint® 0233 Haynes® 282®
Copper/chromium/niobium alloy developed by NASA to additively manufacture parts in need of high-strength dispersion & high conductivity. It retains strength at high temperature, due to the use of chromium and niobium in the alloy, has excellent creep resistance, and a low cycle fatigue life. Velo3D has developed processes that maintains high density in the printed part.
A nickel chromium-ion-molybdenum alloy that possesses excellent forming and welding characteristics. It is easy to fabricate with localized corrosion resistance and oxidation resistance up to 2200 Deg. Fahrenheit (1200 Deg. Celsius)
A precipitation-hardenable nickel-based alloy known for superb tensile strength under extreme pressure and heat. It has rupture strength at temperatures up to and is characterized by its superb fatigue, creep and corrosion resistance in extreme environments.
Made from scandium, aluminum and magnesium alloy. It is the only AM alloy which substitutes for high strength 7000-series aluminum and is stronger than titanium. Outstanding properties in terms of weldability and low thermal expansion. Well-suited for anodizing processes and offers good corrosion resistance.
Titanium 6AI-4V Grade 5
“Velo3D really delivered on our turbopump, including its 3D-printed rotating impeller, all of which functioned perfectly the very first time at 30,000 rpm, using the first prototype.”
Max Haot – Founder & CEO – Launcher
“The unique abilities of Velo3D’s next generation technologies will allow us to minimize the re-design of our products for additive while also reducing the barriers associated with traditional metal additive systems on the build setup, maintenance, and supply chain scalability.”
“This diffuser was the perfect application for additive. When you implement an AM solution to manufacture this kind of part it takes all the complexity away.”
Rolf Meima – Director of Procurement – Siemens Energy
“Over the past few years, many of our customers have inquired about 3D printing. Velo3D’s ability to create parts without having to design them for additive manufacturing makes it stand out compared to other solutions. Its end-to-end solution is very complimentary to our existing offerings and will allow us to greatly improve the supply chain for our customers.”
Campbell Macpherson – EVP of Advanced Manufacturing – Schoeller-Bleckmann Oilfield (SBO)
“We often have to make mission-critical metal parts as required in our rocket design. With Velo3D’s scalable additive manufacturing technology, we are able to use a high reliability process for fabricating parts without compromising design.”
Will Drewery – Vice President of Supply Chain – Astra