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BLT-S825 offers a build dimension of 850mm × 850mm × 2500mm (W×D×H) with a net build height exceeding 2.5m, meeting the demand for integrated manufacturing of ultra-high parts. BLT-S825 has undergone engineering application testing, and its latest design case for engineering applications, the hanging bracket, was also on display at BLT’s booth at the exhibition.

The hanging bracket is a large-size frame component that was previously manufactured by casting or welding. As the size of the component increases, the difficulty and cost of using tooling machines and molds for integrated tooling also increase significantly. BLT optimized the structural design of the hanging bracket, adopting a large number of hollowed-out structures and selecting BLT-TA15 titanium alloy material with low weight and high strength. This greatly reduced the part weight while ensuring functionality and strength, achieving a large-span connection function. The part measures 500mm×200mm×2350mm (W×D×H) and was integrally formed using BLT-S825, demonstrating the process stability of the system.

01 24-Laser Configuration for Higher Efficiency

BLT-S825 is configured with 24 lasers, equivalent to arranging 6 lasers on a 400mm format machine. It supports printing with a large layer thickness of 100μm, achieving a maximum forming efficiency of up to 870cm³/h for more efficient production.

BLT-S825 is equipped with BLT-BP which enables rapid, one-pass efficient slicing of ultra-high parts, reducing the slicing time and preparation time before printing. For instance, a 2.4-meter-high part with 32.56GB of slicing data requires only 1.5 hours for slicing using BLT-S825.

BLT-S825 employs single-recoater double-direction variable-speed powder spreading technology, solving the issue of time-consuming leveling with dual recoaters in large-format systems. During printing, it intelligently adjusts powder spreading speed based on part geometry, implementing variable-speed powder spreading, which is 30% more efficient per layer than constant-speed powder spreading. Consequently, forming this part with BLT-S825 takes only nine days.

02 Mature Solutions Upgraded for Quality Assurance

In 2023, BLT showcased the 20-laser BLT-S800 with air blowing on top at TCT and showcased synchronous laser emission and printing of the 20-laser BLT-S800 at TCT 2024. At the 15^th Airshow China, BLT also presented the 16-laser BLT-S600 which demonstrated high-efficiency printing on site.

BLT-S825 preserves its mature optical and air-blowing solutions, supporting efficient forming with simultaneous emission of four rows of lasers. The system boasts excellent airtightness, with working gas consumption below 10L/min. Its air-blowing solution provides a highly uniform air field, keeping the lens clean for over 700 hours and ensuring more stable forming. For example, BLT-S825 can print multiple hanging brackets in one batch, with high consistency in formed parts and deviations within 5% for various performance indicators across different regions.

BLT-S825 boasts an ultra-high build height and a depth-to-diameter ratio of nearly 3:1. Traditional methods of assembled build cylinders involve a high risk of deformation, potentially causing loss of precision in the build platform and resulting in dimensional deviations in parts. BLT optimized the structure of the build cylinder, reinforcing it while significantly reducing its weight. The optimized cylinder, integrally formed with 3D printing, ensures the strength and manufacturing consistency. Additionally, BLT-S825 extensively incorporates metal 3D-printed parts with optimized designs, enhancing its integration and durability.

Since 2017, BLT has accumulated design expertise in ultra-high Z-axis systems, successively developing systems with build heights up to 1.5m, including BLT-S515, BLT-S615, BLT-S815, and BLT-S1000. Based on the long-term operational experience of over 200 units with high build heights, BLT designed and developed systems with a build height of up to 2.5 meters.

BLT-S825 incorporates BLT’s extensive experience in the build platform, utilizing dual-axis servo drives with high-precision grating scales for closed-loop control of the build platform. While ensuring ultra-high build heights and operational precision, BLT’s machine & system development team has managed to control the overall height of the system, with its external height reaching only 5.5 meters in height, meeting the installation requirements for standard workshops.

BLT-S825 is equipped with a quality monitoring system, including BLT-Powder Spreading Detection, BLT-3D Reconstruction, and BLT-Video Monitoring, enabling real-time key parameter monitoring, image capture, data analysis, and video monitoring for process control and quality traceability.

03 Advanced Configuration for Continuous Production

BLT-S825 is equipped with a parallel long-life filtration system. During the printing process, when the current working filter element meets the conditions for dust removal, it can automatically perform backflushing and then switch to another set of filter elements to continue printing, achieving uninterrupted operation. Additionally, the ash bin is designed with safety features, allowing for wet treatment under an inert atmosphere, enabling safe replacement of the ash bin without interrupting the operation, and effectively avoiding downtime risks from filter element backflushing or ash bin treatment. This meets the continuous production demands of large-format systems, enhancing efficiency and reducing costs.

BLT-S825 offers an integrated or modular powder circulation system. The integrated powder circulation system supports automatic powder recycling, sieving, and supplying within a single unit during printing, enabling more efficient resource allocation and reducing costs and energy consumption. The modular system enables flexible, one-to-many configurations to meet diverse production needs.

04 Redundant Design for Enhanced Safety

BLT-S825 adopts a safety redundancy design for the entire system, establishing a complete safety protection system. It features explosion-proof design, complemented by redundant settings for oxygen content detection systems and pressure sensors, enabling comprehensive monitoring of oxygen content, pressure, and temperature. The system automatically relieves pressure when overpressure is detected. Submodules such as the filter, powder circulation system, and transfer station are all equipped with independent oxygen content, pressure, and temperature detection, ensuring the safe operation of the entire system. BLT-S825 is equipped with argon gas purging safety interlock mechanism to prevent accidental oxygen intake and argon leakage, guaranteeing safe production while ensuring personnel operation safety.

BLT-S825 is equipped with an airtight transfer station. When connected to BLT-WL400 or BLT-XH300, it allows safe depowdering and removal of parts with a full height of 2.5m under inert atmosphere protection through the supporting multi-station and glovebox. This ensures human-powder isolation as well as efficient powder recycling under inert gas protection.

In its pursuit to push the boundaries of aerospace manufacturing, BLT has diligently analyzed the innovative development needs of the aerospace industry and provided dedicated support and service. BLT-S825 has emerged as a result of this commitment. We invite you to visit us at booth H5B12 at Airshow China 2024 to experience the engineering innovations of BLT-S825 and witness its outstanding capabilities in producing large, superior, specialized, and precision aerospace components.

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Since BLT began its research and development in 2014, the BLT-S600 series (BLT-S600/S615) has established itself in the metal additive manufacturing industry with its outstanding performance. In 2016, BLT-S600’s first engineered application, the aero-engine turbine casing, made its debut at Airshow China, marking it as the world’s largest rotary-type part at that time. Today, after numerous iterations, hundreds of units of the BLT-S600 series have been installed globally, widely applied in aerospace, engine, automotive, and other industries to facilitate high-quality, efficient, safe, and intelligent mass production of large-size, complex precision parts.

Highlight 1: Large-format Multi-laser System for Enhanced Printing Efficiency

The build dimensions of the upgraded BLT-S600 have been expanded to 650mm × 650mm × 850mm (W×D×H), and the build volume has increased by 1.66 times, meeting the manufacturing demands for even larger parts. Additionally, the upgraded BLT-S600 can be configured with up to 16 lasers, enhancing efficiency by 3.45 times compared to the four-laser configuration, providing robust support for efficient, high-precision manufacturing of large metal components.

Furthermore, the BLT-S600 utilizes single-recoater double-direction powder spreading technology, significantly reducing the time required for recoater installation and leveling. It intelligently adjusts the powder spreading strategy based on part geometry, implementing variable-speed powder spreading. Compared to traditional constant-speed powder spreading methods, this approach improves efficiency by nearly 30%, achieving enhancement in both powder spreading quality and efficiency.

Highlight 2: Build Cylinder for Integral Forming, Improved Production Reliability

The BLT-S600 employs a build cylinder for 3D printing integral forming which has undergone structural optimization, significantly enhancing cylinder strength and effectively avoiding issues of poor sealing and weakened mechanical performance associated with assembled cylinders. The build platform supports uniform preheating up to 100°C with precise temperature control to prevent
cylinder deformation due to heat, ensuring stable and safe production.

The BLT-S600 incorporates high-strength, corrosion-resistant metal printed parts, not only enhancing its integration level and but also demonstrating its excellent reliability and durability in complex industrial environments.

Highlight 3: Intelligent Detection Function, Enhanced Forming Quality

BLT-S600 integrates multiple intelligent technologies to improve forming quality, including powder spreading detection, scanning detection, and production monitoring. These technologies provide a data foundation for quality control and traceability throughout the printing process.

The powder spreading detection function can intelligently identify and address abnormalities, achieving a powder shortage detection rate of over 99% under normal production conditions. Currently, BLT-S600 is equipped with an upgraded defect detection self-learning platform, which allows users to train recognition models based on specific production scenarios, thereby ensuring high-quality production intelligently. The scanning detection feature, leveraging layer-by-layer scanning and 3D reconstruction technology, can quickly and accurately locate high-risk areas, ensuring part precision and consistency. Additionally, the production monitoring system can not only collect real-time data but also automatically record the status of the build chamber, further enhancing transparency and traceability of the production process.

Highlight 4: Gas and Powder Saving with Self-Circulation, Economic and Eco-Friendly Upgrade

The BLT-S600 leads the industry in sustainable trends with multiple energy-efficient features. Compared to similar products on the market, its gas consumption is significantly lower: the intake is under 5L/min under operating pressure. Additionally, the optical lens cleaning duration is up to 700 hours, ensuring smooth and uninterrupted forming. The BLT-S600 features a long-life filtration system made from flame-retardant materials, which automatically performs backflushing during the printing process. The filtration area is matched with the build format and laser configuration to maximize resource utilization. Besides, the optimized filtration solutions can avoid downtime risks from filter element backflushing or ash bin treatment, ensuring continuous printing while minimizing economic and labor costs.

In terms of automatic powder circulation, the BLT-S600 offers high compatibility, allowing users to select between modular or integrated powder circulation systems based on production needs. The modular powder circulation system supports flexible, one-to-many configurations, thus saving space; while the integrated system offers a streamlined solution for powder sieving, recycling, and supplying within a single unit, minimizing energy consumption and resource dispersion in multi-machine operations.

Highlight 5: User-Friendly HMI for Upgraded Safety and Convenience

The upgraded BLT-S600 significantly improves user experience with optimized HMI (human-machine interaction) and enhanced safety. The gas unit door has been upgraded with a transparent observation window, allowing users to monitor the gas circuit panel data without opening the door. The transfer station is equipped with a pedal-operated Z-axis lifting mechanism for smoother part transfer and cleaning. Additionally, the BLT-S600 features a foldable touch display, with space-saving storage design that enhances user autonomy and comfort. In addition to the main system, its auxiliary powder supplying machine can also be remotely controlled, effectively reducing labor intensity, enhancing efficiency, and ensuring safety.

The BLT-S600 simplifies complex production processes through intelligent hardware and software coordination, greatly increasing operational efficiency. The system supports one-click operations for tasks such as printing preparation, part transfer, galvanometer auto-calibration, and powder circulation. With BLT-AutoCAL, a multi-galvanometer automatic calibration product, calibration accuracy can reach within 0.05mm. When paired with the BLT-MES system, users can link disparate production steps into a highly integrated intelligent chain, thereby supporting the vision of a modern “dark factory”.

BLT adheres to the people-oriented design philosophy, committed to protecting workers’ occupational health. The BLT-S600’s powder-handling areas utilize explosion-proof components coupled with an oxygen monitoring system to ensure a stable inert environment, effectively mitigating explosion risks while expanding the range of material processing. Its laser protective glass and safety interlock mechanism effectively prevent laser leakage, safeguarding operators from radiation. Furthermore, safety designs such as emergency stop switches, grounding protection, and pressure and temperature monitoring combine to create a robust safety system.

At Airshow China 2024, the BLT-S600 will perform real-time printing on site. For more exciting details, visit us at booth H5B12!

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Recently, to address the above problems, Professor Lin Xin’s team at Northwestern Polytechnical University proposed an in-situ high-speed remelting method (HSSR) to simultaneously improve the strength and plasticity of AlSi10Mg alloy produced by PBF-LB/M process. This method uses the heat accumulation in the initial melting stage to alleviate the temperature gradient in the molten pool and increases the solidification rate in the high-speed remelting stage, promoting the grain/honeycomb substructure refinement, columnar to equiaxed transformation (CET) and precipitation of nanoparticles. Compared with aluminum alloys/composites processed by PBF-LB/M process and other methods to date, the resulting materials show excellent strength-plasticity synergy. The research “Achieving superior strength-plasticity performance in laser powder bed fusion of AlSi10Mg via high-speed scanning remelting” was published in Materials Research Letters (IF 8.8).

The researchers used BLT-S210 to prepare samples and conducted comparative studies on PBF-LB/M process samples and high-speed remelting strategy (HSSR) samples, which verified the ideas of the paper and drew research conclusions, As a “brilliant research tool,” BLT-S210 has precise forming accuracy control, a stable and reliable optical system, and a uniform and continuous wind field. Its excellent performance can flexibly respond to diversified needs and provide solid and reliable technical guarantees for the smooth advancement of scientific research projects.

So far, BLT has delivered more than 100 BLT-S210 to clients, promoting cutting-edge research on new materials, new structures, and new functions of metal 3D printing. BLT is deeply engaged in the field of scientific research and is committed to providing machine & system, technical consulting, cutting-edge applications, and other products and services to universities and scientific research institutions, helping Tsinghua University, Peking University, Shanghai Jiaotong University, Beihang University, Northwestern Polytechnical University, and Artificial Intelligence and Robotics Innovation Center of the Hong Kong Innovation Institute of the Chinese Academy of Sciences, among others, to achieve breakthroughs.

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Depowdering aims to remove metal powder from the exterior and interior surfaces of the parts after printing, which has a direct bearing on the mechanical properties and surface finish of the product. However, traditional manual depowdering methods have many drawbacks. For large and complex parts, manual depowdering is extremely difficult and prone to damaging precision structures. Additionally, the flying powder not only contaminates the environment and wastes resources but also poses significant safety risks to operators.

To address these challenges, BLT has introduced BLT-QF400 and BLT-QF600 depowdering machines for metal additive manufacturing, aiming to promote the safe and efficient development of the industry through automation and intelligent technologies.

01 Precise Depowdering for Large and Complex Parts

BLT’s depowdering machine is capable of handling large parts with the maximum load size up to 610mm×610mm×710mm (W×D×H) and load capacity up to 800kg, meeting the depowdering requirements of most components on the market. The operating and vibration systems of the machine effectively remove powder that is difficult to access manually through flipping, rotating, and vibrating. In addition, the built-in shock absorption components protect precision structures. With multi-functional air-duster-blow-gun kits, the machine can perform comprehensive depowdering of complex parts, achieving high-quality depowdering results both externally and internally.

02 Multiple Safety and Explosion-proof Guarantees

BLT’s depowdering machine has obtained CE safety certification and ATEX (Explosion Proof) certification, and BLT’s machines and systems have obtained ISO9001、ISO14001、ISO45001 certifications, providing authoritative and comprehensive safety guarantees. BLT’s machines and systems adopt a fully sealed glove box design to realize human-powder isolation throughout the process. They are also equipped with an inert gas protection system that can monitor the oxygen content and pressure inside the box in real-time, minimizing the risk of powder explosion. Additionally, BLT’s depowdering machine utilizes high-quality components, enhancing the stability and reliability, and further ensuring the health and safety of operators.

03 Intelligent, Visual Operating System

The depowdering machine features an intelligent, visual operating system with powerful self-programming and process management capabilities that allows operators to create customized depowdering programs based on part properties, thus enabling personalized operation. The system also supports archiving depowdering processes, allowing operators to view, retrieve, and optimize historical process parameters. This not only optimizes operational efficiency and precisely controls the depowdering quality but also facilitates quality traceability and management of products, ensuring the efficiency and consistency of the overall production.

04 Green and Clean Powder Recycling

BLT’s depowdering machine features a powder recycling system that automatically collects excess powder into the power buckets for further sieving, significantly reducing labor costs and improving powder utilization, whichis of great significance for enterprises to reduce costs and increase efficiency. The system is also equipped with sealed design and inert gas protection to prevent powder leakage and avoid contamination and harm to the working environment and operators. This aligns with the safe and green development trends of modern manufacturing.

05 Compatible with BLT Machines & Systems for Efficient Production

BLT’s depowdering machine is designed to integrate seamlessly with BLT’s printers and powder circulation machines, forming a systematic and professional powder handling solution. Currently, BLT-QF400 is compatible with BLT-A300/A320, BLT-S310/S320, and BLT-S400; while BLT-QF600 supports BLT-S450 and BLT-S600, offering more powerful powder handling capability and depowdering efficiency. Whether it is for small, complex parts or large, industrial components, BLT’s depowdering machine can provide customers with an all-round and efficient depowdering solution.

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In response to the above problems, the research team led by Professor Chen Hao of Tsinghua University proposed a toughening strategy based on chemically heterogeneous metastable austenite, aiming to explore the potential of chemically heterogeneous austenite design in improving the impact toughness of high-strength steel. Research has shown that the toughness of martensitic steels can be adjusted by introducing an appropriate proportion of chemically heterogeneous austenite into the martensite matrix. The austenite in high-strength steel not only absorbs energy through the transformation-induced plasticity (TRIP) effect produced by deformation-induced martensitic transformation (DIMT), but also promotes local stress release, passivating and deflecting cracks, thus significantly affecting the ductility and toughness of steel. The research “On the role of chemically heterogeneous austenite in cryogenic toughness of maraging steels manufactured via laser powder bed fusion” was published in the international academic journal Acta Materialia.

BLT provided machine support for this research. The researchers used BLT-S210 to prepare samples and successfully prepared maraging stainless steel samples with significantly improved toughness, which verified the research hypothesis and provided a new strategy for the design of high-strength steel with excellent low-temperature toughness. .

BLT is deeply engaged in scientific research and is committed to providing machine & system, technical consulting, cooperative development, and other products and services to clients in this field, with over 330 clients by the end of 2023. Since 2024, BLT has supported Tsinghua University, Peking University, Shanghai Jiaotong University, Beihang University, Northwestern Polytechnical University, Chinese Academy of Sciences, and other universities and scientific research institutions in the fields of aerospace and medical, among others, making numerous breakthroughs in the research of new materials, new structures, and new applications.

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During the printing process, the challenges of sieving metal powder increase significantly due to the powder’s tendencies to adsorb, agglomerate, oxidize, and explode. Furthermore, different metal or alloy powders have diverse physical properties, making it difficult for traditional powder sieving machines or systems to handle the sieving process for advanced materials.

To address these challenges, BLT developed an innovative powder sieving machine.

01 Enhanced Safety Mechanisms for Personnel

Traditional powder sieving machines require the use of forklifts or traveling cranes to lift powder-filled buckets above the screen mesh, which has high requirements for space and auxiliary equipment and also poses safety risks such as mechanical injury and falls from heights. BLT’s powder sieving machine revolutionizes the process by employing a new powder transportation method. This approach eliminates the need to lift the powder bucket during powder sieving, increasing operational convenience while significantly reducing safety hazards, and thus protecting the safety of operators.

02 Safe, Non-destructive Powder Handling

Exposing fine metal powder to air can lead to oxidation, which compromises powder quality. Additionally, certain metal powders are flammable and explosive, and if they reach a certain concentration in the air, they can explode upon coming into contact with an open flame. Therefore, it is important to control oxygen content in the air during metal powder sieving. BLT’s powder sieving machine is equipped with an inert gas protection system throughout the sieving process, effectively lowering oxygen concentration, guaranteeing powder quality, reducing explosion risks, and ensuring safe production.

03 Improved Powder Quality to Ensure Part Quality

BLT’s powder sieving machine combines an ultrasonic system with an oscillating sieving machine. During sieving, the ultrasonic system transmits acoustic energy to the sieve mesh, altering its surface tension. This ensures a more even distribution of powder particles on the mesh, reduces agglomeration, prevents fine powder adsorption, and minimizes mesh clogging, resulting in a more efficient and reliable process for metal powder sieving.

04 One-click Operation for Increased Sieving Efficiency

BLT’ powder sieving machine features a large-particle collection design that automatically gathers large particles to a designated location, preventing powder scattering and simplifying powder collection. Moreover, it integrates gas purging, powder sieving, and ultrasonic control into a one-click intelligent operation that eliminates the need for human intervention and significantly enhances powder sieving efficiency.

05 Flexible Adaptation to Various Production Demands

High adaptability and mass productivity are also one of the highlights of BLT’s powder sieving machine. It caters to different powder circulation solutions, including “1V1”, “1V2” and “1V4”, allowing it to handle both small-batch trial production and mass production with ease. Currently, BLT offers two models, BLT-SF400 and BLT-SF800, both of which are compatible with the full range of BLT’s PBF-LB/M machines & systems, demonstrating its impressive adaptability.

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Stainless Steel

Microscopic structure (×100 times under digital microscope)：

Mechanical properties:

17-4

304

 316L

Compatible systems: BLT-W4000、BLT-W2520、BLT-W2000

Application case: Cabin

Material: 304L stainless steel

Dimension: 360mm×800mm×700mm

Build System: BLT-W2520

Technical Description: The cabin has a complex structure and contains a large number of suspended structures. The traditional method is difficult and time-consuming, failing to meet the client’s needs. BLT responds quickly using WAAM technology to achieve integrated forming of the complex part cast, quickly delivering the cast while ensuring quality and performance.

Aluminum Alloy

Microscopic structure (×100 times under digital microscope)：

Mechanical properties:

205A

114A

 5183

Compatible systems: BLT-W4000、BLT-W2520、BLT-W2000

Application case: Cylinder

Material: 5A06 aluminum alloy

Dimension: φ1075mm×1440mm

Build System: BLT-W2520

Technical Description: The overall structure of the cylinder is conical, with upper and lower flanges. It is traditionally assembled by welding and splicing, which has a long manufacturing cycle and high cost. Based on rich experience in engineering applications, BLT optimizes the technical process, efficiently manufacturing and delivering the part.  Currently, BLT has achieved efficient and high-quality production of large aluminum alloy parts using WAAM technology.

At present, BLT WAAM base has a usable area of about 12,000 square meters, with nearly 100 WAAM systems.

• BLT-W4000 build dimension: 2000mm×2000mm×3000mm (W×D×H),
• BLT-W2520 build dimension: 3600mm×3600mm×1500mm (W×D×H)
• BLT-W2000 build dimension: 1000mm×1000mm×2700mm (W×D×H) or 1200mm×1200mm×1500mm (W×D×H)

BLT has helped clients in the fields of aerospace, machinery, and petroleum industry to achieve efficient production of engineering application parts, and the relevant performance tests of parts have passed client inspection at one time.

The post BLT WAAM Technology Provides Efficient Solutions for Large Complex Parts appeared first on BLT.

BLT’s material research team has developed BLT-Ti, a high-purity titanium powder designed for laser-based powder bed fusion of metals (PBF-LB/M). BLT-Ti’s chemical composition meets both Chinese (GB) and global (ASTM) standards for pure titanium.

BLT-Ti is suitable for parts production in chemical and shipbuilding industries, offering good mechanical properties and excellent corrosion resistance in harsh environments like seawater. In medical applications, BLT-Ti doesn’t contain potentially harmful elements like Al and V, making it more biocompatible and suitable for applications with higher safety requirements.

BLT-Ti is available in 15-53μm, featuring low oxygen content, high purity, high sphericity, few satellite particles, and good flowability. After heat treatment, parts made with BLT-Ti can achieve tensile strengths of 440-500MPa, yield strengths of 360-420MPa, and elongation rates of 25%-35% at room temperature. BLT has successfully achieved large-scale production of high-quality BLT-Ti powder with consistent quality across batches.

Recent research in additive manufacturing of pure titanium has focused on process optimization, microstructure and performance studies, defect management, material innovation, and engineering applications. BLT has optimized its manufacturing processes to overcome issues like pores and cracks in pure titanium forming, thereby improving the quality of titanium parts. As a result, BLT-Ti is now compatible with all of BLT’s marketed machines and systems.​​​​​​​​​​​​​​​​

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