SupportFree Geometries
Break the 45 degree rule with VELO3D. Engineers leverage our unique ability to print at zero degrees to eliminate support structures and print parts that were impossible just a year ago.
SupportFree Metal Additive Manufacturing
Metal Additive Manufacturing or 3D Printing, is mainly a welding process featuring rapid solidification of melt pools. During solidification and cooling, the parts experience thermal and residual stresses. Supports serve two purposes: first, as anchors to restrain the part and keep it from moving due to thermal distortion and second, to enable heat transfer. Temporary support structures are an inconvenient necessity in Direct Energy Deposition (DED) and traditional Powder Bed Fusion (PBF) and often require post-print machining operations. Post processing adds costs and processing delays. More importantly, it limits the design freedom of this new manufacturing method.
VELO3D separates itself from existing powder bed fusion solutions with its 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 eliminates the need for post-processing, but it overcomes the “45 degree rule” – a boundary requiring supports at angles less than 45 degrees. VELO3D frees designers to build the impossible – unlocking a wealth of designs that can be produced with additive technology.
Low Angles
AM has relied on support structures to anchor parts to the build plate and for thermal management for decades. As an industry we have come to rely on those structures to assist with building low angles less than 45 degrees. But, these low angle geometries are the same features that tend to be created inside of an assembly’s inaccessible, internal channels during part consolidation. By using supports to anchor parts to the build plate, we have anchored our industry to prototyping. Until now.
Current State
- 45deg limitation for low angles or overhangs
VELO3D
- ZERO Degree Overhangs
- No supports needed – even horizontal – in some cases
- Can build flat to build plate
- Dramatically less post processing
- High quality, predictable surface finish
Large Inner Diameters (ID)
If we could build large apertures without supports; with a high-quality surface finish; and with tight geometric control, then we could make consolidated assemblies in AM. VELO3D SupportFree capabilities do just that. By leveraging process simulation, feature specific processing, closed loop melt pool control, and a non-contact recoater, VELO3D has reduced the reliance on support structures for internal geometries.
CURRENT STATE
- 4-10mm ID
VELO3D
- Up to 100mm unsupported ID
- Able to print manifolds, volutes, crossovers, etc
High Aspect Ratios (AR)
High aspect ratio structures, with features that are very tall but not very wide, are common occurrences on many parts designed for heat exchangers. These feature large, thin surfaces to allow for effective heat transfer across the interface. However, high aspect ratio structures can present challenges when building parts due to their inherent lack of mechanical stability, which makes them relatively easy to bend or break on contact.
Current State
- 8:1 aspect ratio
VELO3D
- 3000:1 aspect ratio possible
- Able to print high aspect ratio parts (heat exchangers) and assemblies
FreeFloating
VELO3D is working to offer the ultimate in metal 3D printing – fully SupportFree, free floating parts. These parts are printed Free-floating in powder, with no requirement to anchor parts to the build plate and with no reliance on sintered cake of powder.
Current State
- Impossible
VELO3D
- Single point initiation to build parts free floating
- Complex lattice structures possible
- Large full build height possible
Watch our videos to see SupportFree in action:
