What is VELO3D's Sapphire build volume?
315mm diameter, true z height of 400mm with 25mm thick build plate.
What is the laser configuration?
Dual, full range, 1kW lasers.
What materials do you support?
We currently support IN718, Ti6Al4V.
What kind of postprocessing is required after a part is printed?
As with other powder bed fusion systems, some post-processing is required to remove supports. Sapphire includes SupportFree capabilities and generally requires significantly fewer supports than conventional AM systems. On conventional AM systems, low angle surfaces typically require supports at less than 45 degrees. With Sapphire, low angle surfaces can be built, unsupported, to less than 10 degrees. See our white papers for details.
Do you offer print preparation software, or how do I prepare the print?
FlowTM print preparation software is included with each purchase of a VELO3D solution. Flow™ ensures predictable print outcomes while significantly reducing print preparation time. Driven by a powerful, integrated simulation engine and co-developed with Sapphire™, Flow unlocks parts not previously possible with Additive Manufacturing (AM).
What import file formats do you support?
Unlike other systems that are based on mesh import, Flow is designed with native CAD formats in mind. Using CAD data 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 meshes are derived from CAD models. Translation file formats such as .stp or .x_t are also supported.
Can you import lattice structures?
Yes, Flow supports the output from many different commercially-available lattice generation tools.
Do you accept slices generated in other preparation software?
No. Leveraging our simulation capabilities requires that the file be a three-dimensional description of the part.
What surface roughness is achievable?
In IN718 we print parts with surface roughness as low as 3 microns SA. This result is geometry dependent.
What is the maximum inner diameter of a tube or hole size that can be printed without supports?
We are currently printing 40mm ID horizontal tubes without supports.
What is the lowest angle of a design that Sapphire can print without supports?
In general, VELO3D supports printing angels <10 degrees without supports.
Are the supports auto-generated or can I override/design my own?
Flow provides guidance as to what should be supported, and the user can select regions of interest and apply supports where they see fit. Regions (saved selection sets) make the application of supports and processes easy and organized. Flow features beam, wall, thin wall, and tree support types.
What are the external dimensions of the machine?
Total system footprint is 2.1 m per side and 2.4 m tall. (for more detail see Sapphire system specifications)
How long does it typically take after a build ends before the next build can begin?
Our build change-over automation eliminates the need for human intervention between builds, reducing the time between one build ending and the next beginning to less than 15 minutes. The system eliminates the need to clean the laser window, empty the powder overflow, manually level the build plate, and purge the chamber.
Do I have to interrupt a build to refill powder?
All consumables maintenance can be done without interrupting a build, and the system holds sufficient powder for over two full builds.
What monitoring and diagnostics do you report?
Sapphire auto-generates an Intelligent fusion report for each build, giving the operator a summary of the quality of the print and the performance of the machine.
What happens when the system discovers an error?
The build is paused, and the operator is notified. Remote alerts (i.e. email) are supported.
How does the system respond to a power failure?
Sapphire has a built-in UPS that allows it to ride through facility power fluctuations, and to gracefully shut down in the event of a major and sustained power outage.
Can I reuse the overflow/unused powder?
Yes, by keeping oxygen levels extremely low (<10ppm), powder reuse is significantly extended over conventional metal AM systems.
Does the recoater wear during a build?
VELO3D developed a unique noncontact recoater that does not wear or need regular replacement.
What is your technical support commitment to a customer?
We believe that selling a unit is just the beginning of a professional relationship. We are committed to support in all forms (Phone, email, in-person). Your success is our success.
What is SupportFree?
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. However, after printing, engineers must remove the supports through post processing steps. 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 below 10 degrees, as well as large diameters and inner tubes up to 40mm 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. See more on our SupportFree page: https://velo3d.com/products-technology/support-free/
What new capabilities does VELO3D provide for contract manufacturers?
VELO3D enables contract manufacturers to change their design rules, bid on parts previously thought too risky, manufacture at a higher quality, and leverage SupportFree processes to build the impossible. Most 3D Printed metal parts limit their overhang angles without supports to ~ 45 degrees. To go below, conventional printers rely on supports that are often laborious to remove and require extensive post processing. VELO3D allows designers to build overhangs below 10 degrees without supports. By eliminating internal supports, manufacturers are able to print parts that would typically be considered impossible. See more in our contract manufacturer’s section: https://velo3d.com/applications/contract-manufacturers/