Manufacturing Structurally Sophisticated Implants Without Supports

As the medical industry moves towards personalized custom implants, innovations in metal additive manufacturing (AM) are transforming spinal, cranial and orthopedic surgery: The integrated end-to-end metal AM system comprised of the Sapphire™ 3D printing system, Flow™ print preparation software, and Intelligent Fusion™ technology from Velo3D (Campbell, CA) can manufacture structurally sophisticated implants without supports to ensure better patient experience and lower cost.

Sapphire is a laser powder bed metal 3D printing system for high volume manufacturing that can build complex geometries, including designs with overhangs that are less than 5 deg and large inner diameters without supports – something previously unheard of in the AM industry. The machine has two 1 kW lasers and a patented non-contact recoater, with a build area that is 315 mm in diameter and 400 mm in the Z-axis. This gives it the capacity to manufacture individual large parts or a batch of smaller components simultaneously. To deliver superior part-to-part consistency, its integrated in-situ process metrology enables closed loop melt pool control that reduces deformation and variability between parts. To maximize productivity, the system contains a module that enables automated change-over with offline unpacking. Changeovers between builds are done autonomously within 15 minutes so the machine can operate continuously.

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Flow print preparation software includes support generation, process selection, slicing and simulation of complex part designs to validate execution feasibility before the build. Geometrical feature-driven processing enables low angles below 5 deg. In addition, deformation correction technology enables the user to produce parts without the need for iterations, achieving a first print success rate of up to 90 percent. Flow minimizes the need for supports, reducing typical support volume by three to five times, which removes or reduces the laborious post processing necessary with conventional approaches. Enabling an end-to-end integrated workflow, Intelligent Fusion is the technology that powers Flow software and the Sapphire system. Intelligent Fusion optimizes the AM process by combining thermal process simulation, print prediction, and closed-loop control during print execution.

Velo3D systems are currently used by original equipment manufacturers (OEMs) and manufacturing service providers. “Four years ago, we set out with the bold vision of creating technology that could manufacture parts with any geometry to take additive manufacturing mainstream,” said Benny Buller, the founder and chief executive officer of Velo3D. “Our approach relies on creating deep insights in the fundamentals of physics, enabled by research, characterizing and understanding of core mechanisms, developing intelligent process control through software simulation, and in-situ metrology. We are now working with some of the top OEMs and service bureaus creating parts that were once considered impossible.”

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Velo3D is working in a collaborative partnership with 3D Material Technologies (3DMT; Daytona Beach, FL), a leading metal additive manufacturing services bureau. “Additive manufacturing has the potential to be revolutionary,” commented Ashley Nichols, the general manager of 3DMT. “Systems are getting bigger but not delivering on the promises of metal additive manufacturing. Through our partnership, 3DMT and Velo3D are unlocking new applications, pushing the envelope of what is currently considered possible. We look forward to continued success and to delivering on the promises of the potential of metal additive manufacturing.”

Velo3D, 511 Division Street, Campbell, CA 95008, 408-610-3915, Ashley Nichols, [email protected], www.velo3d.com.