Aerospace systems integrator Intergalactic is using Velo3D's Rapid Production Solutions (RPS) service to produce IN718 microtube heat exchanger headers for an aviation program with 'aggressive system-level test deadlines.'
According to the two companies, these components are intended for use in a cabin air heat exchanger assembly designed for a mass-produced commercial aircraft. They are being manufactured with Velo3D's Sapphire XC metal additive manufacturing platform.
Using additive manufacturing, the components boast large-radius geometries and 'sweeping' low-angle transitions that are 'typically restrained' by the 'mechanical recoaters used in legacy laser-powder-bed-fusion systems.' The Sapphire XC's non-contact recoater, along with Velo3D's advanced parameter sets, is said to have enabled these designs to be printed with minimal internal support structures.
What's more, the RPS service also allowed Intergalactic to move from design to printed parts in just a couple of weeks, supporting an accelerated path to component testing and system integration. The use of Velo3D's IN718 parameter sets shortened the time to first articles and is said to have provided the groundwork for a long-term supply chain strategy, since the design can be produced across any validated Sapphire or Sapphire XC system.
"Customers with aggressive program timelines rely on Rapid Production Solutions to get hardware fast without redesign and without lengthy development cycles," said Velo3D Chief Revenue Officer Michelle Sidwell. "RPS embodies Velo3D's mission to remove friction from innovation and give our customers a true competitive edge."
"Building these heat exchanger headers on the Sapphire XC supported Intergalactic's goal to meet its system-level test schedule and established the groundwork for a scalable path to a distributed supply chain for future production," added Intergalactic Supply Chain Leader Rhett Burton.
