Setting a new bar for metal additive manufacturing, the Sapphire system uniquely enables engineers to realize designs with overhangs lower than 5-deg., as well as large inner diameters without supports. A Laser Powder Bed Fusion system, its innovative design is built around ground-breaking process insights. As a result, Sapphire is capable of building complex geometries considered impossible with conventional metal additive manufacturing systems, while delivering consistent, reliable, and cost-effective performance, reducing cost per part by 30-70%.
The Sapphire system is designed from the ground up with high volume manufacturing in mind. It comprises a 315 mm diameter by 400 mm height build envelope, with high throughput dual laser operation. To deliver superior part-to-part consistency, integrated in-situ process metrology enables first-of-a-kind closed loop melt pool control.
With its first-of-its-kind, closed-loop melt pool control processing, the system reduces build deformations and ensures tight part-to-part tolerances, enabling production consistency. Every build includes a comprehensive Intelligent Fusion report providing system information and metrology data, while uptime is increased by greater than 10% over traditional systems by reducing setup, changeover times, and scheduled maintenance. Sapphire also provides end-to-end support from site preparation, installation, qualification, training, service, to pre and post-build application support, plus a full suite of remote, on-site, and web portal support services.
To maximize productivity, the system comprises a module to enable automated change-over, so a new print can start without operator involvement within 15 minutes.
Features:
- Large ø315 mm, z-axis 400 mm build envelope
- Dual 1kW laser operation
- Available materials: IN718, Ti6Al4V
- Zero-contact recoater increases yield
- Integrated in-situ process metrology enabling closedloop melt pool control
- Sub-10 ppm O2 atmospheric control
- Automation module to enable build changeover without operator involvement within 15 minutes
- Evergreen powder management solution with automated changeover and offline unpacking
- Service response time insurance
- Class 1 Laser Product
Enabling Critical Part Designs
- Overhangs down to 5° angles without supports
- Large unsupported inner diameters of 40 mm
- Minimum feature size and wall thickness below 250 microns
- Available materials: IN718, Ti6Al4V
Product Development Acceleration
- Physics-aware print preparation software
- Expanded design envelope
- Typically a 3 to 5 fold reduction in support volume
- Fewer print iterations
- Resulting in up to 90% first pass success
- Simple or no post processing
Unprecedented Consistency and Quality
- In-situ process metrology
- Closed-loop melt pool control
- Surface finish: <3 µm SA
- Improved part-to-part consistency
Lowest Cost Per Part
- Typical throughput: > 60 cm3 /hour of IN718
- Cost Per Part: < 50% of alternative
- 24/7 operation on single operator
- Automated changeover module
- Offline unpacking
