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At TCT Asia 2025, BLT showed what’s possible to produce here and now with real-world machines and systems, real parts and real results. For manufacturers looking to scale, speed up or cut costs, here’s what stood out at the show.

BLT-S1025: more height, more lasers, more output
The newly launched BLT-S1025 raised the bar for industrial-scale production. Built on the success of the BLT-S1000, this next-gen system offers a towering 2500 millimeter build height and up to 32 lasers. This makes it ideal for oversized components and high-throughput workflows.

An aircraft part printed on the BLT-S1025 drew heavy attention at the show, showcasing both scale and precision in one single build.

Compact but powerful: the upgraded BLT-S400
BLT also unveiled the upgraded BLT-S400, designed for space-conscious production environments. With a compact 3.36 square meter footprint and smart powder circulation, the system offers higher throughput without compromising quality. Its improved Z-axis stability, enhanced powder spreading system and long-life filter make it ideal for serial production. Over one million 3C blanks have already been manufactured with the new BLT-S400.

Smarter processes, faster cycles
BLT’s new smart powder-spreading system adapts in real-time using intelligent algorithms. It boosts spreading speeds up to 300 millimeters per second while maintaining consistency. This is especially the case across large build platforms. In a nutshell – more output, same precision.

BRIGHTENLINES: end-to-end AM production
Automation took center stage at the show with BRIGHTENLINES. This is BLT’s new modular production line for additive manufacturing. From powder handling to substrate disassembly, the system offers a fully integrated solution to scale AM production without the usual manual bottlenecks.

Materials that perform under pressure
With two recently launched high-performance alloys, BLT showed what’s possible when material and machine are developed together.

BLT-K438/In738 is a nickel-based superalloy for aerospace and energy sectors. It offers corrosion resistance, high-temperature strength and structural stability. A turbine blade printed with this material was on display.

BLT-AlAM300C is a thermal-conductive aluminum alloy used to produce lightweight liquid cooling plates. These parts, printed on the BLT-A320, are already being explored for electric vehicles and electronics thanks to their efficient heat transfer and low pressure drop.

In the aerospace and aviation field, the application of metal additive manufacturing technology has been very extensive. However, due to the complex design of the internal structure of the parts and the high precision requirements, the use of traditional manufacturing methods requires higher costs and longer time, and the production efficiency and cost control of enterprises are facing significant challenges. In the face of such a difficult situation, BLT has set up an independent R&D team from the development stage of the first machine, focusing on the development of intelligent software and hardware systems designed specifically for metal additive manufacturing.

After more than ten years of research and development experience, BLT has created a complete process monitoring system, including BLT-Intelligent Recoating Detection, BLT-3D Reconstruction and BLT-Video Monitoring module. The system includes the whole process monitoring from the beginning of manufacturing to the completion of pickup, which can realize visualized easy operation and intelligent real-time, help efficient and intelligent quality management of the production process, and save nearly 500,000 invisible costs for customers every year.

BLT-Intelligent Recoating Detection

BLT-Intelligent Recoating Detection can intelligently recognize the complex environment of different models of equipment in the process of printing and spreading powder, with the advantages of high detection accuracy, high finished product rate, and reduced labor costs. The software can intelligently recognize abnormal conditions such as lack of powder, squeegee jamming, and powder spreading cuts. The identification process does not need to worry about the impact of the printing environment, the detection success rate of up to 98%. The whole inspection process supports printing without stopping, and realizes the self-treatment of powder laying problems, which greatly reduces the time and labor costs.

BLT-3D Reconstruction

BLT-3D Reconstruction uses a high-quality industrial camera to take pictures of the forming section layer by layer, realizing real-time tracking of the forming process and accurately locating model defects during the printing process. It can clearly and accurately efficiently locate the defective areas of model slices, which is easier to trace when optimizing at a later stage; this module can not only track the formed section in real time, but also simulate the section about to be printed, which makes it easy to correct possible future errors in a timely manner, and improves the stability of the overall printing process. It takes only 3s to rebuild 12,000 layers with this function, which is in line with the demand for efficient, multi-layer reconstruction of large-size parts in the aerospace and aviation industry.

BLT-Video Monitoring

BLT-Video Monitoring plays a role in tracing the quality of the printing process, and equipped with a very clear operating screen, support for local one-key access. It supports video recording of the entire 3D printing process, and you can choose to assemble more than 4T capacity of large hard disk, as long as you set up a customized time interval, the module can be automatically stored in high-definition video and pictures in accordance with the format, to improve the convenience of the operation of the manual late quality traceability.

BLT-Intelligent Recoating Detection, BLT-3D Reconstruction and BLT-Video Monitoring cover the whole time period of process quality monitoring and can be connected to the BLT-MES system, so that users can grasp the production status in real time, which is convenient for remote inspection and later quality traceability. BLT’s process monitoring system combines software and hardware to optimize process parameters with advanced technology, ensure a more stable manufacturing process, and achieve high-efficiency and low-cost manufacturing of aerospace and aviation components.

The 2024 Formula Student China (FSC) concluded with thrilling performances, marking a milestone for motor racing events. Since 2016, BLT has been a committed sponsor of FSC/FSAE teams, continuously exploring metal 3D printing’s potential in lightweight automotive design and innovation.

In this competition, BLT-sponsored teams—TJU (Tongji University) Racing Team, BIT (Beijing Institute of Technology) Racing Team, and HIT (Harbin Institute of Technology) Racing Team—all secured second prize at the national level. This achievement highlights not only the teams’ technical expertise but also the pivotal role of BLT’s comprehensive support in the design and manufacturing of racing components, which enabled breakthroughs in weight reduction, strength enhancement, and thermal management efficiency.

Enhancing Structure and Performance for Racing Innovation

In high-performance race cars, structural integrity and weight reduction are critical. BLT leveraged metal 3D printing to provide tailored solutions that enhanced durability, reduced weight, and improved mechanical properties for key vehicle components. For TJU Racing Team, BLT helped address structural weak points in the steering housing, where the connections were prone to fractures. By adopting a wrap-around connection method, the revised design significantly improved strength and durability while enhancing mechanical performance.

Additionally, the Dre24 rear pillar was redesigned with a barrel-surrounding structure and printed with BLT-AlMgScZr, BLT’s high-strength aluminum alloy, balancing lightweight design and structural integrity. For brake calipers, BLT applied topology optimization to minimize material usage while maintaining rigidity, further refining the connection structure to achieve both weight reduction and enhanced performance. These components were manufactured using BLT-S600 machine, ensuring precision and superior mechanical properties.

In collaboration with BIT Racing Team, BLT refined the design of critical components like pillars and steering mounts through topology optimization and generative design. This approach enabled significant weight reduction in the parts without compromising strength, which is crucial for meeting the strict performance requirements of racing conditions. These parts were printed by BLT-S400 machine using BLT-AlSi10Mg, ensuring high precision and mechanical reliability for racing cars.

Optimizing Thermal Management for Better Performance

Thermal management plays a crucial role in race cars. BLT supported HIT Racing Team in optimizing their motor cooling system, manufacturing a custom-designed water jacket using BLT-AlSi10Mg by BLT-S400 machine. The design incorporated a Z-shaped water channel, maximizing heat dissipation area. A modular design simplified assembly, while thermal paste-filled gaps further enhanced heat transfer, ultimately extending motor lifespan and efficiency.

BLT’s commitment to motorsports engineering extends beyond sponsorships, unlocking innovation in automotive component manufacturing. In the inaugural BLT Racing Component Optimization Design Competition, TJU Racing Team took first place and BIT Racing Team secured second. The judging panel, composed of industry leaders and experts from leading automotive brands, provided professional insights and guidance, helping student teams optimize their design strategies and manufacturing processes.

With the competition concluding, BLT reaffirms its commitment to pioneering metal 3D printing applications in automotive engineering. By advancing innovation and collaboration, the company invites global partners to join forces in redefining the future of motorsports technology and driving progress together.

Foldable phones come with big challenges, especially in hinge design. When phone brand OPPO set out to design their Find N5 model, the goal was ambitious: To create one of the slimmest, most durable foldable phones without compromising strength. Here’s how we at BLT helped them.

A key issue in the design process of the Find N5 was screen creasing. This is caused by an insufficient bending radius when the phone folds and unfolds repeatedly. Durability was another concern, as most conventional metal hinges struggle to survive 200,000 folding cycles without deforming.

Weight was also an issue. In many foldable models, the hinge alone accounts for over 10 percent of the phone’s total weight. This makes it difficult to achieve a truly lightweight design. Then there is reliability. Dust intrusion and mechanical wear are also common hinge failures, especially in high end devices where users expect smooth performance over years of use.

To solve these issues, OPPO needed to redesign its hinge from the ground up using stronger materials and more advanced manufacturing methods. That is where BLT’s metal AM and proprietary metal powders came into play.

The ideal material for a stronger, lighter hinge

To help OPPO achieve its vision for the Find N5, BLT applied aerospace grade titanium 3D printing to the phone’s hinge system. Titanium offered an ideal combination of strength, lightness and durability, while metal AM allowed for precise structural optimization, impossible to achieve with traditional manufacturing.

Through extensive testing and refinements, the BLT team successfully reduced the hinge thickness from 0.3 mm to just 0.15 mm. That is an incredible 50 percent reduction, making the hinge much slimmer while maintaining rigidity and strength. The new design also resulted in a 120 percent increase in structural strength, making the hinge far more resistant to mechanical wear. Screen deformation was also reduced, thanks to a 36 percent boost in hinge rigidity.

Durability was another critical factor. The new hinge design was tested for 100,000 folding cycles under extreme temperature conditions, ranging from -20 °C to 50 °C, ensuring that it could withstand real world use without failure. The Find N5 boasts two TÜV Rheinland certifications.

Perhaps most impressive was the efficiency of production. Thanks to multi laser AM technology, BLT was able to produce 300 hinges in just 25 hours, a pace that would have been very difficult to achieve using conventional methods.

Precision engineering – the Skyfold hinge

BLT’s role in this project went beyond material selection. The company also played a crucial part in optimizing the hinge structure for lightweight durability.

One of the most complex parts of the hinge is the wing plate, which shapes the droplet like bending radius when the phone is folded. This component supports the smooth unfolding of the flexible screen while reducing stress on the panel, helping to prevent visible creases over time.

Another key part is the outer rotating shaft middle frame, which plays a critical role in absorbing energy from accidental drops or impacts. This enhancement not only improves long term reliability. It also contributes to the phone’s overall structural integrity.

By leveraging metal AM’s design flexibility, BLT helped OPPO engineer a hinge that is thinner, stronger and longer lasting. Simply put – a new standard for foldable phone technology.

The continuous evolution of foldable phones

The pursuit of compact, functional mobile devices is not new. In 1989, Motorola introduced the StarTAC, the first flip phone, which popularized the idea of a folding design for portability. In 2004, the RAZR V3 refined the concept, becoming an iconic device known for its slim profile.

Fast forward to today and foldable screens are bringing back the clamshell concept but with advanced display technology and larger, more immersive screens. OPPO, Samsung and Huawei are among the manufacturers leading this shift, pushing hinge technology to new limits.

Taking center stage of this innovation pace is precision engineering and materials science, exactly where metal AM excels.

BLT taking lead in next-gen consumer electronics

BLT, Bright Laser Technologies, is at the forefront of metal additive manufacturing. We work across industries from aerospace and medical to consumer electronics.

By applying aerospace-grade production standards to 3C products, we help companies develop lighter, stronger and more efficient designs. From foldable phone hinges to wearables and precision components, metal AM is enabling high-performance consumer devices.