Velo3D Sapphire XC

$2,000,000 – $3,500,000 Updated 2026-03-17

Key Specifications

build volume

Ø600 mm x 1000 mm Z

number of lasers

laser power

8 × 1,000 W fiber lasers (8 kW total)

layer thickness

30 – 100 µm

build rate

Up to 60 cm³/hr (material and geometry dependent)

minimum overhang angle

0° (support-free down to horizontal surfaces)

Overview

The Velo3D Sapphire XC (Extra Capacity) is a large-format laser powder bed fusion (LPBF) metal 3D printer with an 8-laser, 1 kW-per-laser configuration and a 600 mm diameter × 550 mm tall cylindrical build volume. Launched as Velo3D's production-scale flagship, the Sapphire XC addresses the aerospace and space propulsion industries' demand for larger, more complex metal AM parts built without the support structure constraints that limit competing LPBF platforms. Velo3D's core intellectual property — the non-contact recoater and Flow print preparation software — enables the Sapphire XC to print low-angle overhangs down to 0° and internal channels with diameters down to 1 mm without supports, a capability directly relevant to rocket engine combustion chambers, turbine blades, and aerospace fuel system components.

The 8 × 1 kW laser configuration provides substantial build rate compared to single- and dual-laser systems. Lasers operate in parallel across the full 600 mm build diameter with inter-laser stitching managed by Velo3D's closed-loop Intelligent Fusion process control, which monitors melt pool geometry in real time via photodiode and pyrometer arrays. The system automatically adjusts laser power and scan speed to maintain consistent melt pool conditions layer-by-layer, reducing porosity and microstructural variability that would otherwise require destructive testing to detect.

The Sapphire XC is designed as a production system rather than a development tool. It includes automatic powder loading and unloading, an inert argon atmosphere with continuous oxygen monitoring and purge, and an integrated sieving and recycling loop for unmelted powder. Velo3D's Flow software generates build files directly from CAD, and the Assure quality system provides layer-by-layer build monitoring data exportable to QMS systems for full traceability — a requirement for AS9100-certified aerospace production environments.

Velo3D supports the Sapphire XC with qualified material parameters for Titanium Ti-6Al-4V, Inconel 718, Inconel 625, Hastelloy X, aluminum AlSi10Mg, and copper alloys. The system is in production use at major space launch and defense aerospace suppliers, where its support-free capability eliminates post-processing operations that are impractical on thin-wall aerospace hardware.

Full Specifications

Parameter	Value
Build Volume	Ø600 mm x 1000 mm Z
Number Of Lasers	8
Laser Power	8 × 1,000 W fiber lasers (8 kW total)
Layer Thickness	30 – 100 µm
Build Rate	Up to 60 cm³/hr (material and geometry dependent)
Minimum Overhang Angle	0° (support-free down to horizontal surfaces)
Minimum Internal Channel Diameter	1 mm without supports
Accuracy	±0.1 mm or 0.1% of dimension (whichever is greater)
Supported Materials	Ti-6Al-4V, Inconel 718, Inconel 625, Hastelloy X, AlSi10Mg, copper alloys
Atmosphere	Argon inert atmosphere, continuous O2 monitoring
Process Monitoring	Velo3D Intelligent Fusion — photodiode and pyrometer melt pool monitoring
Software	Velo3D Flow (build prep), Assure (quality monitoring)
Machine Weight	~8,500 kg (18,740 lbs)
Size	8.53 x 5.00 x 4.75 m
Lasers	Eight 1 kW
Throughput	Up to 800 cc/hr
Surface Finish	5–15 μm Sa (typical)

Specifications sourced from velo3d.com — verified 2026-03-28

Strengths & Limitations

Strengths

Support-free printing of overhangs down to 0° eliminates complex support removal operations on thin-wall aerospace components
8 × 1 kW lasers covering the full 600 mm build diameter deliver high throughput for large aerospace and space propulsion hardware
Intelligent Fusion closed-loop melt pool control reduces layer-to-layer variation, improving part consistency across the build volume
Assure quality system provides full layer-by-layer traceability data compatible with AS9100 and aerospace quality management requirements

Limitations

Cylindrical build envelope limits rectangular part packing efficiency compared to competitors with rectangular build volumes
Capital and operating costs are among the highest in LPBF — system, powder, and maintenance require substantial recurring investment
Velo3D's closed material ecosystem limits qualification to Velo3D-approved powders, restricting flexibility for novel alloys

Best For

Space propulsion manufacturers printing rocket combustion chambers, turbopump housings, and nozzles with complex internal cooling channels Aerospace OEMs producing titanium and Inconel structural components requiring low-angle overhangs without support structure Defense suppliers needing full build traceability and in-process quality documentation for flight-critical hardware

Frequently Asked Questions

01 What makes the Velo3D Sapphire XC different from other LPBF machines?

The Sapphire XC's key differentiator is support-free printing down to 0° overhangs, enabled by a non-contact recoater and Intelligent Fusion closed-loop process control. Most LPBF systems require support structures below 30–45° overhangs, which are costly to remove and can damage thin-wall features. Velo3D eliminates this constraint, making parts like hollow turbine blades and rocket chamber cooling channels printable in a single setup.

02 What materials does the Velo3D Sapphire XC support?

Velo3D has qualified parameters for Ti-6Al-4V, Inconel 718, Inconel 625, Hastelloy X, AlSi10Mg, and copper alloys on the Sapphire XC. Parameters are developed and validated by Velo3D; the system does not support open user customization, which ensures consistency but limits flexibility for novel alloys.

03 How large are the parts the Sapphire XC can produce?

The Sapphire XC has a cylindrical build volume of 600 mm diameter by 550 mm tall, accommodating rocket engine combustion chambers up to roughly 24 inches in diameter, large impellers, turbine cases, and aerospace structural brackets. The cylindrical envelope is optimized for the round parts common in aerospace propulsion.