China3D printingChromalloy, a subsidiary of Sequa Corporation, which provides integrated manufacturing and repair solutions to manufacturers and operators of gas turbine engines, has selected sapphire metal from privately funded Silicon Valley company VELO3D.3D printingSystems for the manufacture of aftermarket parts solutions for energy and aviation gas turbines. VELO3D’s Sapphire printers have been used in aerospace applications in the past, but this marks the first time its industrial technology has been tested in the critical energy and aerospace MRO (maintenance, repair and operations) markets.
VELO3D’s manufacturing facility is located in Campbell, California, where final assembly and testing of all Sapphire 3D metal printers takes place. All systems are shipped from this location.
By using Sapphire 3D printingMachines, Chromalloy should be able to speed up the supply chain as additive manufacturing offers greater flexibility and shorter lead times than most traditional MRO supply chains such as welding and casting.As MRO applications in the energy and aerospace sectors require rapid, low-volume production of old parts without spending time redesigning them for3D printing, For Chromalloy,3D printingParts must have intrinsic value because they are3D printingof. Otherwise, printing itself is a novel technology. VELO3D’s unique build capabilities and material density create high value by reducing post-processing requirements.
Approved by the Federal Aviation Administration (FAA) and European Aviation Safety Agency (EASA), as well as many other National Aviation Administrations (NAAs), and certified by ISO and NADCAP, Chromalloy’s solutions are designed to reduce manufacturing and operating costs, and Extend the life of gas turbine engines.By installing industrial sapphire in the field of manufacturing and repair services3D printingThe software, which comes standard with VELO3D’s user-friendly automated Flow pre-print software and Assure QA and control system, can help ageing gas turbines keep operating speed costs low.
Chromalloy continues to find innovative alternatives for our customers to extend the life of their engines and reduce their MRO costs. VELO3D additive manufacturing equipment provides a unique, practical solution to our proprietary LifeX customer solutions. “
Chromalloy gas turbine engineer II Zack Hopkins, with the company’s newly delivered Sapphire® metal additive manufacturing system.
Chromalloy selected the VELO 3 DS apphire® system to significantly impact the economics of future maintenance, repair and operations (MRO) projects in its aviation and energy markets. VELO3D will enable this machine to have3D printingQualification for nickel-based superalloys, including Hastelloy® X, which are known for their strength and durability in high temperature environments. Hopkins’ responsibilities include project leadership supporting Chromalloy’s innovation strategy and technology roadmap.VELO3D is known for its patented SupportFree printing process, which helps users create parts with more complex geometries. This capability means that older parts traditionally manufactured using brazing, casting and welding methods do not need to be built for the new manufacturing process (3D printing) and redesign, which certainly reduces the barriers to part transition.
“For complex gas turbine combustor components with limited aftermarket or high replacement costs, the Sapphire system will enable Chromal to produce hardware on demand without the high NPI (new product introduction) tooling costs and lead times of other methods,” Whitton Say.
Additionally, VELO3D will enable Chromalloy’s machines to have3D printingQualifications for nickel-based superalloys, which include the robust Hastelloy X material whose durability makes it ideal for high-temperature environments.
“As an industry leader in aerospace MRO, Chromal Thermoalloys are an excellent partner for us. They have the expertise to open up an entire market class of parts,” said Benny Buller, CEO and founder of VELO3D. “With the flexibility to produce high-value, high-mix, low-volume aerospace parts, AM can enable supply chains to scale to market and customer-specific needs.”
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