Today, Mears Machine Corporation (Indianapolis, Indiana), a leader in precision machining solutions, has purchased its 4th Sapphire XC printer to bolster its additive manufacturing capabilities in response to customer demand. This order underscores Mears Machine's commitment to adopting advanced manufacturing technologies and follows the previous purchase of three Velo3D Sapphire XCs in 2024.

The new order is expected to be delivered in the second quarter of 2025. Initial customer production hardware completed printing in April. The Velo3D Sapphire XC printer sets itself apart in the laser powder bed fusion industry with its unique print capabilities and large format. The printer uses eight 1-kilowatt lasers and can produce parts 600 mm in diameter and 550 mm in height.

The new Velo3D Sapphire XC printer at Mears Machine will be configured to produce parts in Haynes 282 alloy. Haynes 282 is a strengthened superalloy developed for high-temperature applications, primarily for aerospace propulsion systems, industrial power generation, nuclear power and critical CO2 systems. It possesses a unique combination of strength, thermal stability, and fabricability not found in currently available commercial alloys. Printed parts also have better weldability, creep resistance in the range 1200-1700F (649-927C), oxidation properties and great thermal stability.

"Integrating the Velo3D Sapphire XC printer into our operations has represented a significant leap forward in addressing the evolving needs of our existing customers. The new industries and customer base attracted by this capability has exceeded our expectations," said Roger Mears, Executive Chairman of Mears Machine. "This technology empowers us to efficiently deliver complex, high-quality components to our customers. Coupled with our world-class machining capability and post-process supply chain management experience, we are positioned as a leading partner in the additive manufacturing landscape. Our customers' demands have increased, and we have met production with Velo3D's highly scalable additive manufacturing solution, which makes us unique in the industry." Mears Machine has extensive experience machining and welding nickel superalloys enabling a full-service solution to be provided to customers.

Haynes 282 is a Nickel-based superalloy which has greater strength at higher temperatures, improved corrosion and creep resistance compared to Inconel 718. Applications for gas turbines include combustion liners, vane rings and nozzle components. Haynes 282 is challenging to machine, and Additive Manufacturing can reduce the amount to be machined.