SupportFree for metal additive manufacturing creates a new paradigm, opening up new opportunities for engineers to bring more parts to production. It enables manufacturers to make impossible parts and design without limits.
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 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.
We distinguish between four use cases: Accelerated, Possible, Innovative, and Ultimate.
Use case - Accelerated
With traditional Manufacturing, some parts are complex, requiring a multi step manufacturing process.
Conventional Additive Manufacturing solutions lack advanced thermal deformation simulation. Engineers typically overcome this by using supports to anchor parts to the build plate in an effort to control part deformation. This results in increased design/prep/print/post-process time.
With VELO3D, engineers do not require supports for overhangs greater than 10 degrees.VELO3D‘s simulation engine allows for more accurate part geometry by accounting for and correcting part deformation. This grants engineers more design freedom and results in fewer supports and less post processing time.
- Reduced development time
- 90% first article print success
- Faster time to market
Use case - Possible
Some parts with complex internal structures are only possible with multi step, low yield, traditional milling and welding processes.
Conventional Additive Manufacturing solutions are a poor fit due to the high number of internal supports that are impossible or extremely difficult to access. This results in costly, unpredictable production results.
With VELO3D, engineers do not require supports for overhangs greater than 10 degrees which enables them to design without internal supports on parts with complex internal geometries. This reopens the opportunity to 3D print parts considered impossible. Rethink what is possible. Now, engineers can leverage the power of AM on more parts than ever before: faster time to market, lower cost, and higher yield manufacturing.Read the White Paper
Use case - Innovative
Today, designers have hit the limit of conventional AM, isolating an enormous capability into a small design space. The potential for AM has not been realized.
Meanwhile, world challenges continue to grow. Innovation accelerates to speeds never seen in the history of mankind. We need new solutions. Yet, additive manufacturing waits, mostly unused, on the sidelines.
With VELO3D, engineers can unlearn the old design rules. We can cut free of the supports that anchor AM down. Through an integrated approach to co-developing software, hardware, and processes, VELO3D is empowering designers to go further. Design without limitations and unlock the future.
Use case - Ultimate
VELO3D is working to offer the ultimate in metal 3D printing – fully SupportFree: The ability to print Free-floating in powder, no requirements to anchor parts to the build plate, no reliance on sintered cake of powder, no supports – anywhere.
With VELO3D, engineers will be able to finally design without limitations.
This is the Future of Additive ManufacturingSee SupportFree in Action