Velo3D Large Format System

$5,000,000 - $10,000,000+ Updated 2026-03-17

Key Specifications

build volume

1,000+ mm diameter x 1,000+ mm H (configuration dependent)

laser type

Yb-fiber laser array

laser power

Multiple x 1 kW (configuration dependent)

number of lasers

8–16 (configuration dependent)

layer thickness

50 – 100 µm (material dependent)

min feature size

~200 µm

Overview

The Velo3D Large Format System represents the apex of Velo3D's SupportFree metal additive manufacturing platform, designed for aerospace and defense structures that exceed the capabilities of even the Sapphire XC family. While Velo3D has not published a single finalized commercial product sheet under this name, the Large Format System concept — and early systems delivered to aerospace customers — targets build envelopes exceeding 1 meter in diameter, with multiple high-power fiber lasers scaled to match. The system brings Velo3D's core technology advantages (SupportFree overhangs, Intelligent Fusion monitoring, non-contact recoating) to part sizes previously served only by casting, forging, or directed energy deposition.

The engineering challenge Velo3D addresses with the Large Format System is not simply scaling up a powder bed. At diameters exceeding 1 meter, maintaining uniform powder layer deposition, consistent inert atmosphere quality, and coordinated multi-laser beam management become significantly more complex. Velo3D's non-contact recoater design, originally developed for the standard Sapphire to handle overhanging geometries, becomes even more critical at this scale — even minor powder bed disturbances propagate across a larger area and are harder to recover from. The Intelligent Fusion system scales to manage larger laser arrays, using real-time thermal feedback to prevent hot spots and maintain dimensional accuracy across the full build area.

Target applications for the Large Format System include full fuselage frames and bulkheads for next-generation aircraft, large satellite bus primary structures, submarine pressure hull components, and launch vehicle fuel tanks and structural adapters. These are applications where the aerospace and defense prime contractors have traditionally had no LPBF option — the choice was between casting lead times measured in months, expensive forging dies, or welded fabrications with associated inspection and qualification burden. A large-format SupportFree LPBF system that can produce these components as single near-net-shape parts represents a fundamental shift in how aerospace structures are manufactured.

As a cutting-edge, partially developmental platform, the Large Format System is sold directly to aerospace and defense prime contractors under long-term development and production agreements rather than as a standard catalog item. Pricing is negotiated on a program basis, with indicative system costs in the $5,000,000–$10,000,000+ range depending on build envelope specification, laser count, and integration requirements. Buyers are typically defense prime contractors and space agencies with both the capital and the technical staff to operate systems at this level.

Full Specifications

Parameter	Value
Build Volume	1,000+ mm diameter x 1,000+ mm H (configuration dependent)
Laser Type	Yb-fiber laser array
Laser Power	Multiple x 1 kW (configuration dependent)
Number Of Lasers	8–16 (configuration dependent)
Layer Thickness	50 – 100 µm (material dependent)
Min Feature Size	~200 µm
Min Overhang Angle	Sub-5 degrees (SupportFree technology)
Recoater Type	Non-contact recoater (scaled)
Technology	Laser Powder Bed Fusion (LPBF) — SupportFree, large-format
Materials	Inconel 718, Inconel 625, Ti-6Al-4V, Hastelloy X, Al F357, Stainless Steel
Atmosphere	Argon inert gas
Process Monitoring	Intelligent Fusion real-time monitoring — full envelope
Software	Flow (print preparation), Assure (quality management)
Power Requirements	3-phase, 480V, 200A+ (facility engineering required)

Strengths & Limitations

Strengths

Build envelopes exceeding 1 meter in diameter enable single-print production of aerospace fuselage frames, satellite primary structures, and rocket tanks that have no precedent in LPBF
SupportFree technology at large format eliminates internal supports in complex structural shells and vessels where support removal would be physically impossible
Intelligent Fusion monitoring scales to large laser arrays, maintaining thermal control and dimensional accuracy across the entire large-format build area
Non-contact recoater at large format prevents the catastrophic blade crashes that would be inevitable with conventional recoater designs on warped or distorted tall structures
Direct Velo3D engineering support and custom integration available for defense and aerospace prime contractor programs requiring purpose-built specifications

Limitations

System pricing of $5M–$10M+ places the Large Format System in a category accessible only to defense prime contractors, national laboratories, and large aerospace OEMs
Not a standard catalog product — procurement involves program-based agreements, long lead times, and extensive facility planning and commissioning
Powder inventory, handling, and recycling systems for builds exceeding 1 meter diameter are highly specialized and require dedicated facility infrastructure beyond the machine itself

Best For

Aerospace prime contractors printing full fuselage frames, bulkheads, and wing primary structures as single LPBF parts for next-generation aircraft programs Defense prime contractors producing large submarine pressure hull components, missile body structures, and armored vehicle structural elements Space agencies and commercial launch providers printing large rocket fuel tanks, structural adapters, and satellite primary bus structures National defense laboratories and advanced manufacturing research programs developing large-format LPBF processes for classified aerospace and defense applications

Frequently Asked Questions

01 Is the Velo3D Large Format System a commercial product?

The Large Format System exists as a platform concept and has been delivered to defense and aerospace prime contractor customers under program-based agreements. It is not sold as a standard catalog item with a fixed specification sheet. Velo3D works with potential customers to define the exact build envelope, laser count, and integration requirements for each program. Contact Velo3D directly for current availability and specifications.

02 How does the Large Format System differ from the Sapphire XC 1MZ?

The Sapphire XC 1MZ is a commercial product with a defined specification (600 mm diameter x 1,000 mm height, 8 x 1 kW lasers). The Large Format System targets build envelopes beyond the XC 1MZ — diameters exceeding 1 meter — for aerospace structures that cannot be produced even on the XC 1MZ. The Large Format System represents the current frontier of Velo3D's platform scaling roadmap.

03 What types of aerospace structures justify a Large Format System?

Structures that benefit most are those currently produced as multi-piece welded or brazed assemblies due to their size exceeding casting and forging capabilities, including full-ring fuselage frames (1,000–3,000 mm diameter), large satellite primary structural boxes, rocket interstage adapters, and submarine pressure hull sections. For these applications, a single-print LPBF part eliminates weld seams, reduces inspection burden, and can reduce manufacturing lead times by months.

04 What facility requirements does the Large Format System need?

The Large Format System requires custom facility planning for each installation. At minimum, buyers should anticipate high-bay space with ceiling heights exceeding 5,000 mm, three-phase power at 200A or greater, very high-volume argon gas supply, extensive powder handling and recycling infrastructure, and reinforced flooring for systems that may exceed 15,000 kg. Velo3D provides dedicated facility engineering support for every Large Format System installation.

05 Who are the current users of the Velo3D Large Format System?

Velo3D does not publicly disclose all Large Format System customer names due to defense and program confidentiality requirements. Velo3D has publicly discussed large-format aerospace and defense applications with multiple space and defense prime contractors. Given Velo3D's customer base includes companies in the US defense and space industrial base, most Large Format System users are in those sectors.