Velo3D Sapphire 64

The Velo3D Sapphire 64 is the large-format iteration in Velo3D's Sapphire product line, featuring a 1,000 mm diameter × 600 mm tall cylindrical build volume and 24 fiber lasers at 1 kW each — one of the highest laser count and build volume combinations available in production LPBF. The Sapphire 64's primary target is the serial production of very large aerospace, defense, and industrial components that previously required multiple-piece assemblies or conventional fabrication routes. By printing these parts as a single near-net-shape structure, the Sapphire 64 eliminates joining operations, reduces part count, and enables internal geometry complexity impossible with subtractive or casting methods.

Like all Sapphire platform machines, the Sapphire 64 incorporates Velo3D's non-contact recoater and Intelligent Fusion closed-loop process control. These technologies are even more critical at the Sapphire 64's scale, where maintaining consistent powder bed quality and melt pool conditions across a 1-meter build plate requires precision that traditional contact recoaters cannot reliably deliver. Intelligent Fusion monitors thousands of individual melt pools per second with photodiode and pyrometer arrays, enabling the system to detect and respond to anomalies in real time across all 24 laser zones.

The Sapphire 64 shares the Sapphire platform's support-free printing capability, printing overhangs from 0° and internal channels from 1 mm diameter without support structures. At this scale, that capability is transformative: large rocket engine structures, satellite bus frames, aircraft nacelle components, and offshore energy equipment that would require extensive support scaffolding on conventional LPBF machines can be printed clean on the Sapphire 64, dramatically reducing post-processing labor and the risk of part damage during support removal.

Velo3D offers the Sapphire 64 as a production system to be operated in customer facilities or through Velo3D's network of contract manufacturing partners. Qualified materials include Ti-6Al-4V, Inconel 718, Inconel 625, and Hastelloy X, with the Assure quality system providing the AS9100-compatible layer-by-layer documentation required for aerospace production. The Sapphire 64 represents the current frontier of production-scale LPBF for the most demanding large-part aerospace and space applications.