-- Hardware questions --
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 down to 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/
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 are the external dimensions of the machine?
Total system footprint is 6ft 11in (2.1m) per side and 7ft 11in (2.4m) tall.
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.
Does the recoater wear during a build?
VELO3D developed a unique non-contact recoater that does not wear or need regular replacement.
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.
How does the system respond to a power failure?
Sapphire has an optional UPS that can be purchased to enable it to ride through facility power fluctuations, and to gracefully shut down in the event of a major and sustained power outage.
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 happens when the system discovers an error?
The build is paused, and the operator is notified. Remote alerts (i.e. email) are supported.
-- Software questions --
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 previously impossible to print with Additive Manufacturing (AM).
What import file formats do you support?
Unlike other systems that are based on mesh-based workflows and thus require mesh import, Flow is designed with native CAD workflow 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 CAD models are converted to meshes,. Flow supports the import of the majority of native CAD formats, as well as Translation file formats such as .stp , iges, or .x_t.
Can you import lattice structures?
Yes, Flow supports the output from many different commercially-available lattice generation tools in file formats such as .3mf, .ltcx, .csv.
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.
Are the supports auto-generated or can I override/design my own?
Flow supports users with the ability to generate and select regions of interest and apply supports where they see fit. Regions (saved selection sets) make the application of supports and application of sub-processes easy and organized. Flow features beam, wall, thin wall, and tree support types and recognizes as Support type, supports that were modeled in CAD.
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.
-- Materials questions --
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 down to 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 materials do you support?
We currently support IN718, Ti6Al4V.
What is the lowest angle of a design that Sapphire can print without supports?
In general, VELO3D supports printing angles down to 10 degrees without supports.
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 highest aspect ratio that can be printed?
We are currently able to print up to full build height at minimum thickness for a maximum of 3000:1 aspect ratio.
What surface roughness is achievable?
Depending upon the geometry, we can print parts with surface roughness below 5 microns SA.
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.