Sapphire XC

The Sapphire XC is an SLM 3D printer from Velo3D with a 600 x 600 x 550 mm build volume.

Specifications

Velo3D Sapphire XC: Technical Specifications

Laser System

The Sapphire XC is equipped with eight 1 kW fiber lasers (8 kW total laser output), each with its own independent galvanometric scanner covering the full ⌀600 mm build area simultaneously.

Optics / Scanner

Each laser has a dedicated galvo scanner. The patented non-contact recoater uses controlled airflow instead of mechanical contact with the powder bed, eliminating recoater-part collisions that plague conventional LPBF at scale.

Build Volume

Cylindrical chamber: ⌀600 mm × 550 mm height: approximately 5× the cross-sectional area of the original Sapphire (⌀250 mm).

Chamber / Shielding Gas.

Calibration

Calibration: Velo3D Sapphire XC

Laser Optical Calibration

Flow automatically verifies alignment of all eight lasers via integrated metrology sensors before each build. Tolerance < 25 µm per laser head. Optical degradation flags require mirror cleaning or replacement before proceeding.

Powder Bed Health Check

Assure analyses per-layer camera imagery for powder coverage uniformity.

Common defects

Common Defects: Velo3D Sapphire XC

Porosity (gas porosity / lack-of-fusion)

The most common LPBF defect: caused by mismatched laser energy density (too low → lack-of-fusion; too high → keyhole porosity) or powder moisture. Assure identifies anomalous optical emission zones in real time. Remedy: optimise parameter set with test coupon; dry powder at 80–120 °C.

Hot Cracking (solidification cracking)

Typical in nickel superalloys (IN718, Hastelloy X) with wide solidification ranges.

What it is used for

Use Cases: Velo3D Sapphire XC

Aerospace Structural Components

SupportFree technology enables production of fuel injectors, heat exchangers, and pneumatic manifolds with internal conformal channels impossible to machine. Customers include Ursa Major, Launcher, and SpaceX supply chain partners.

Rocket Engines.