Applications with demanding functional, performance and precision requirements are poised to quickly move to metal additive manufacturing. VELO3D Sapphire™ was designed to address the most advanced challenges providing a broad design space, with little or no post processing and superior quality.
Metal Additive Manufacturing for Medical
Increasing innovation in rapid prototyping and metal AM bring major transformations in spinal, cranial and orthopedic surgery.
Growing interest and adoption of additive manufacturing methods is driven by higher flexibility in design, elimination of expensive tooling, reduced material consumption and faster time-to-market for high-value components.
A New Future For Medical Implants
VELO3D enables structurally sophisticated implants that can be manufactured without supports ensuring better patient experience and lower cost. The ultimate vision of the industry is personalized custom implants. With its unique, innovative metal additive manufacturing solutions, VELO3D brings the industry much closer to this vision.
The production of orthopedic implants can be laborious, multi-phased and inefficient. Traditional implants require review and replacements, lengthy procedures that involve multiple medical specialists and are an expensive and painful process for the patient.
Metal additive manufacturing revolutionizes the process of orthopedic implant production with the ability to manufacture complex designs that are optimized for performance and integration with the human body and that are timely and affordable.
While making big steps toward a new era of orthopedic surgery, conventional additive manufacturing solutions still have limitations that make production of volumetrically optimized structures difficult. Fully optimized designs are still a challenge to make and lengthy post-processing that impacts time and cost are still a reality.
Velo3D enables the most advanced solution for full serial production of orthopedic parts such as hip cups, by producing free floating parts that do not require attachment to the build plate or supports. The parts are easy to clean and don’t require attachment to the build plate. Truly floating, the parts can also be nested in the full build volume allowing concurrent production of over 400 parts in a single build.
Cost effective low volume medical manufacturing is reaching new heights.
Light-weighting is an important aspect for multiple industries. Lattice structures provide high strength-to-weight ratios and bring enormous benefits to buy-to-fly ratio, cost of used material, cost reduction and sustainability.
Light structures like these are nearly impossible to cast and are uniquely enabled by additive manufacturing.
Conventional AM systems have limitations with printing lattice angles and aspect ratios of the beams. Most of these systems cannot assure mechanical consistency, which has a dramatic effect on design allowable guard banding. There are also significant yield concerns due to recoater and part interactions, potentially leading to part and system damage.
Velo3D excels at building lattice structures. Our Flow software accepts native lattice file formats, and many lattices can be built free-floating in the powder bed, leveraging the full build volume for production quality volume builds. The zero-contact recoater avoids system damage, enabling high aspect ratio and low angle struts, while the closed-loop melt pool control assures consistency. As a result, development time for light-weighted designs is significantly reduced.