Velo3D Sapphire XC Metal 3D Printer
Key Specifications
Build Envelope
Laser Configuration
Layer Thickness
Materials
Minimum Overhang Angle
Oxygen Level
Overview
The Velo3D Sapphire XC (Extra Capacity) is a large-format laser powder bed fusion metal 3D printer engineered specifically for aerospace, defense, and energy sector applications requiring oversized metal additive parts without support structures on challenging geometries. The Sapphire XC's key differentiator is its SupportFree manufacturing capability — Velo3D's Intelligent Fusion process and non-contact recoating system enable printing of low-angle surfaces (down to 0 degrees from horizontal) without support structures that must be removed post-print. The 600mm diameter x 550mm tall cylindrical build envelope (the largest of the Velo3D family) handles full-size aerospace components like rocket engine chambers, turbine shrouds, and heat exchangers. Eight 1kW lasers operate simultaneously to maximize productivity. The Sapphire XC is used by SpaceX, Launcher, and other space propulsion manufacturers for liquid rocket engine components in Inconel, Ti-6Al-4V, and other high-temperature alloys.
Full Specifications
| Parameter | Value |
|---|---|
| Build Envelope | 600 mm diameter x 550 mm tall (cylindrical) |
| Laser Configuration | 8 x 1 kW fiber lasers |
| Layer Thickness | 30 - 90 µm |
| Materials | Inconel 625/718, Ti-6Al-4V, AlSi10Mg, 316L SS, Hastelloy X |
| Minimum Overhang Angle | 0 degrees (SupportFree) |
| Oxygen Level | < 10 ppm |
| Build Rate (Ti-6Al-4V) | Up to 85 cm³/hr (8-laser) |
| Dimensional Accuracy | ±0.1 mm |
| Software | Velo3D Flow (prep) + Assure (quality) |
| Recoating | Non-contact (no blade marks on part) |
Strengths & Limitations
Strengths
- SupportFree printing of 0-degree surfaces enables rocket engine geometries impossible on other LPBF machines
- 8-laser system for maximum throughput on large components
- 600mm diameter build for oversized aerospace and energy parts
- Non-contact recoating prevents part damage on delicate overhangs
- Flow + Assure software provide integrated quality monitoring and part certification data
Limitations
- Very high capital cost
- Cylindrical build volume limits rectangular part configurations
- Limited to specific supported materials (expanding but not as broad as EOS)
- Requires specialized operator training for SupportFree process setup
Best For
Frequently Asked Questions
01
Standard LPBF machines cannot print surfaces below about 45 degrees from horizontal without support structures. Velo3D's SupportFree technology uses a non-contact recoating system and Intelligent Fusion process control to print surfaces as low as 0 degrees (horizontal). This enables rocket engine chambers with internal cooling channels, turbine shrouds, and heat exchangers that cannot be made on conventional LPBF systems.
02
Primary users are aerospace and space propulsion (liquid rocket engines, turbine hot section components), defense (hypersonic vehicle components), and energy (gas turbine fuel nozzles, heat exchangers). The Sapphire XC is specifically designed for the complex internal geometries of propulsion components.
Videos
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