Velo3D’s Non-Contact Recoater Blade

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Velo3D’s non-contact recoater blade technology helps engineers achieve greater design freedom in additive manufacturing (AM). Traditional AM processes, such as laser powder bed fusion (LPBF), have several limitations that can restrict design freedom. Recoater blades in conventional LPBF machines must often be in contact with the powder bed to spread powder evenly. This can create defects in the printed parts and limits the complexity of part designs.

Velo3D’s non-contact recoater blade eliminates these limitations. The blade is suspended above the powder bed and uses a controlled air flow to spread the powder evenly. This allows for the creation of complex, intricate designs while reducing defects and build failures.

The Benefits of Velo3D’s Non-Contact Recoater Technology

Improved Part Complexity

A non-contact recoater enhances both manufacturing capacity and process stability by expanding the gap between the recoater blade and the powder bed to several times the designated layer thickness. Despite this increase, the method still ensures a consistently thin and consistent “working layer” of following each recoating cycle.

Enhanced Low-Angle Geometries for Maximum Performance

Extra clearance during the recoating process accommodates a degree of part protrusion, enhancing the feasibility of manufacturing low-angle overhangs , even down to a 0° angle relative to the horizontal plane. This substantially reduces or eliminates the need for supports to anchor the part, without compromising surface integrity, and helps control the flow of fluid or transfer of heat in the final part.

Increased Part Quality

Velo3D’s non-contact recoater enables the creation of “high aspect ratio features” like thin walls or pins. The increased gap between the blade and the powder bed diminishes the shearing forces generated during the recoating stage. As a result, we can print these features irrespective of build orientation with little to no risk of deflection, deformation, or breakage.

Additional Resources

3Din30: Exploring Velo3D’s Cutting Edge, Non-Contact Recoater Blade Technology

People often ask us how Velo3D can print the most advanced geometries, so for our next episode, and for the first time, we’re pulling back the curtain in a live Q&A session about our unique non-contact recoater technology. Watch now.

Blog: Achieving AM Design Freedom with Velo3D’s Non-Contact Recoater Blade

We provide a high-level overview of the LPBF metal AM process, explain how conventional metal AM systems are limited, and dive into the Velo3D approach, which allows for true design freedom when printing parts with our fully integrated solution.

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