Metal in Motion: Redefining critical part production with Velo3D
End-to-end manufacturing solution
The Bike3D The end-to-end metal additive manufacturing solution, consisting of Flow print preparation software, the Sapphire family of metal 3D printers, Assure real-time quality control and validation software, and its underlying Intelligent Fusion manufacturing, has redefined what is possible with metal AM and has helped engineers produce critical components that perform better, weigh less, and feature more complex geometries than ever before, while reducing production time .
Flow Print Preparation Software
To flow is responsible for prescribing the manufacturing process for the Sapphire family of printers. The software’s detailed process library eliminates the need to develop new parameter sets. With over two dozen standardized recipes, engineers can analyze the part while Flow automatically applies the correct recipe to each feature. This saves months of development and reduces the need for specialized technicians.
Sapphire family of metal 3D printers
The Sapphire family of printers are next generation powder bed fusion laser AM printers. With a redesigned optical center, optimized gas flow and unique non-contact capper, Sapphire printers are capable of printing today’s most advanced geometries. Plus, with nearly 1,000 distinct sensors and built-in calibration routines, Sapphire printers are ready to meet the rigorous quality standards of today’s most demanding industries.
The Velo3D Sapphire family of printers includes
- Sapphire — 315mm Ø x 400mm z with two 1kW lasers
- Sapphire 1MZ — 315mm Ø x 1000mm z with two 1kW lasers
- Sapphire XC — 600mm Ø x 550mm z with eight 1kW lasers
Ensures quality control software
To assure Quality control software enables visibility into every layer of a part’s construction through real-time, multi-sensor, physics-based excursion detection algorithms and provides unprecedented traceability of machine health, part integrity and construction reports.
Smart fusion is the underlying manufacturing process that ties together and facilitates all aspects of the end-to-end Velo3D solution, which includes print preparation software (Flow), advanced metal printer (Sapphire) and insurance software quality (Assures).
Flow imports native CAD design files and automatically identifies part regions based on local geometric attributes (e.g. overhang angle, width, etc.) and specifies custom weld instructions designed to generate the best quality for every intricate part feature.
The Sapphire printer then executes these instructions using a next generation internal laser scanning system combined with a new powder coating mechanism to produce metal parts of unparalleled complexity and quality.
Finally, Assure software reports detailed progress and quality information in real time using thousands of system sensors to provide users with comprehensive quality control.
Intelligent Fusion unifies and manages all of the above, including information flow, sensor data from over 950 sensors, and advanced printing technology for precise control of all printing.
Redefining critical part production with Velo3D
Metal AM applications are growing and innovative companies are using the Velo3D end-to-end solution to revolutionize their designs. Learn more on how the company’s solution has transformed the process of designing and manufacturing critical parts such as microturbines, high-pressure tanks, heat exchangers, static mixers and turbopumps.
- Learn how to print fully optimized parts with the toughest geometries to maximize performance
- See why space, energy and aviation innovators are using Velo3D to overcome large-scale production challenges, improve supply chain consistency and reduce lead times
- Learn how an airline used Velo3D to successfully consolidate dozens of separate parts into a single basic component structure
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