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Thanks to ongoing innovations and cost reductions in additive manufacturing technology, the market adoption of this technology has been steadily increasing. Consequently, the additive manufacturing industry is experiencing rapid expansion. In line with the ongoing progress of the “Era of Mass Production” in metal additive manufacturing, Xi’an Bright Laser Technologies Co., Ltd. (BLT) achieved significant technological advancements in 2023, contributing to the higher quality development of the industrial manufacturing sector.

Figure 1: BLT Printing System Family

Empowering Large-Scale Production in Aerospace Industry

In the aerospace sector, BLT addressed the unique requirements of metal additive manufacturing by introducing a range of formable high-temperature alloys and titanium alloys. Notably, the LPBF process (Laser Powder Bed Fusion) saw the release of the high-temperature alloy material BLT-In738. This material addresses challenges like high crack sensitivity and low density during the LPBF process, making it suitable for applications in the hot-section components of aerospace engines and gas turbines. Furthermore, BLT-Ti64 powder exhibited exceptional mechanical performance and corrosion resistance, while BLT-Ti demonstrated moderate mechanical properties, high ductility, and ideal corrosion resistance—both highly applicable in the aerospace industry. Breakthroughs were achieved with BLT-Ti2AlNb powder and BLT-Ti65 powder, exceeding the traditional limitations of titanium alloys for applications below 600℃, making them well-suited for high-performance aerospace components. Additionally, BLT also introduced BLT-TiAl4822 powder, specifically designed for Powder Metallurgy (PM) and Electron Beam Melting (EBM) processes, offering a potential weight reduction for high-temperature structural components in aerospace engines by partially replacing nickel-based high-temperature alloys.

Figure 2: Impeller printed in BLT-In738

In response to the substantial demand from the aerospace industry for large-scale metal additive manufacturing printing systems, BLT introduced a comprehensive platform solution in 2023. This includes the BLT-S615, BLT-S815, and the engineering-application-validated BLT-S1500—an impressive 26-laser, extra-large format printing system. The development of these advanced multi-laser, large-format printing systems is customized to address the diverse production requirements of aerospace customers. This facilitates the simultaneous manufacturing of large and medium-sized components while also supporting the small-batch production of large-sized components.

Figure 3: BLT Intelligent Factory

Revolutionizing Cost Efficiency, Quality, and Productivity across Heavy Industries

In the automotive sector, BLT leveraged the printing machine BLT-S400 to assist the Tongji Electric Vehicle Team in the batch production of high-strength aluminum alloy components, including columns, rocker arms, flanged ear plates, and water-cooled casings. The formed parts exhibit excellent consistency, meeting strength, and stiffness requirements while achieving a notable weight reduction. This innovative approach addresses the requirements for small-batch pre-research and trial production of automotive components. In the medical field, the printing machine BLT-S310 facilitated WEDO Bio’s efficient mass production of standard sample bone medical devices. The final parts exhibit excellent dimensional accuracy and consistent quality performance, aligning with stringent product quality requirements. In the field of molds, VEM- a worldwide mold manufacturing brand procured BLT-A320 equipment for the mass production of molds. The enhanced stability of the mass-produced molds has significantly shortened the delivery cycle of parts, thereby greatly enhancing production efficiency.

Figure 4: The implant samples designed and printed by the WEDO Bio team

In response to market demands and challenges associated with batch production in the industrial sector, BLT took a significant step in 2023 by upgrading and releasing multiple laser configuration solutions for BLT-A400, BLT-S400, and BLT-S450. These configurations aim to enhance the production efficiency and stability of printing machines, offering the industrial sector a broader range of high-quality, equipment-centric solutions for cost reduction, quality improvement, and efficiency enhancement in batch production.

Efficient powder circulation is an imperative requirement for batch production in the “Era of Mass Production” in metal additive manufacturing. Catering to diverse production scenarios in the aerospace and heavy industries, BLT has introduced several highly effective powder circulation solutions. For scenarios requiring continuous production with multiple printing machines, a production line-oriented powder circulation scheme is available. Alternatively, for the demand for continuous production with large-scale printing systems, an integrated powder circulation solution can be implemented. This adaptability ensures that BLT effectively caters to varied production requirements in both aerospace and other heavy industries, aligning with the imperatives of the “Era of Mass Production” in metal additive manufacturing.

Figure 5: BLT-S400 and its Powder Circulation System

Pioneering Process and Software Advancements for Cost-Efficient and Streamlined Batch Production

Significant strides have been made in advancing non-support technology, greatly enhancing overall efficiency in batch production, especially when processing intricate structural components through the LPBF (Laser Powder Bed Fusion) process. Traditionally, support structures are added during manufacturing to ensure component integrity, only to be removed in post-processing. Yet, the inclusion of supports presents challenges such as time-consuming and material-intensive pre-processing and forming stages. The subsequent support removal can be labor-intensive and time-consuming, and issues may arise when supports within certain structures cannot be entirely removed, impacting the yield of the final product. These challenges have hurdles for the LPBF process from transitioning into large-scale production. Leveraging its comprehensive industry expertise, BLT has innovated across equipment, powder, printing path planning, and process parameter tuning. In 2023, BLT introduced a non-support printing technology solution capable of printing structures with angles below 30 degrees. Since its market debut six months ago, this technology has found application in various industrial batch production, reducing labor and energy consumption in post-processing while ensuring high production efficiency.

Revolutionizing Intelligent Manufacturing through self-developed Software Ecosystem

Metal 3D printing technology has emerged as a modern and intelligent metal processing method, evolving in tandem with the flourishing computer industry. Scaling up production with metal 3D printing equipment necessitates the integration of numerous intelligent production and management tools. By the end of 2023, BLT has successfully established a robust software ecosystem catering to a production line featuring over a hundred metal additive manufacturing systems. This accomplishment underscores BLT’s unwavering dedication to propelling intelligent manufacturing through an all-encompassing and interconnected software infrastructure. BLT-BP V2.0, implemented in the preprocessing phase, covers BLT’s entire equipment, accommodating numerous BLT printing systems configured with dozens of lasers. Specifically customized to specific large-scale production scenarios such as shoe molds and electronics applications, the system configures customized and efficient parameter schemes, comprehensively enhancing the overall preprocessing efficiency.

The equipment control software, BLT-MCS, has reached new heights of customization. It caters to diverse industries including aerospace, engines, energy, automotive (including new energy vehicles), consumer electronics, molds, research & academia, vocational education, and more. The software is equipped with industry-specific modules, addressing the needs of large-scale production, and focusing on aspects like quality monitoring, quality traceability, and efficiency improvement.  It consistently refines optional functions like intelligent powder spreading, 3D reconstruction, visual correction, and automatic grafting to proactively address the ever-changing needs of various industries.

The production line management powerhouse, BLT-MES 2.0, is purpose-built for large-scale manufacturing, drawing insights from BLT’s extensive portfolio of several hundred metal additive manufacturing production lines. Positioned as an essential companion for the intricacies of “lights-out factories” in metal additive manufacturing, this production line management BLT-MES 2.0, boasts an intelligent scheduling module enabling remote task assignment and cross-process data tracing. It links the entire production process and facilitates intelligent collaborative management across group-wide, multi-region production lines. The IoT module enables functionalities like data collection and online reporting, supporting third-party software integration. This integration ensures the smooth incorporation of metal 3D printing processes into industrial manufacturing, laying the groundwork for a comprehensive intelligent upgrade in the industrial manufacturing sector, ultimately leading to reduced costs.

Looking ahead to the Future, Breakthroughs in Technology are Poised to Open up new Exciting Possibilities for further Advancements in Large-scale Production.

In early 2023, BLT officially introduced the additive manufacturing process for hard alloys, specifically tungsten steel, and showcased various new applications of tungsten steel at the TCT Asia 2023 exhibition. Tungsten steel is known for its high hardness, wear resistance, and corrosion resistance, and is widely utilized in various industrial cutting tools and drill bits. BLT’s additive manufacturing process for hard alloys addresses the challenges posed by traditional methods in producing intricate tungsten steel components. The final components not only exhibit low porosity but also lack crack defects. Notably, this technique exhibits particular advantages in manufacturing products with intricate structures, such as channels and nozzles. As these technological strides unfold, the landscape of metal additive manufacturing holds the promise of even greater possibilities in the realm of large-scale production.

BLT’s innovative process for hard alloys has broadened the range of materials that can be effectively utilized in additive manufacturing. This breakthrough not only charts a new course for the production of industrial products within metal additive manufacturing but also underscores the vast potential and broad application scenarios that exist within the industrial landscape. Looking ahead, metal additive manufacturing is poised for further technological breakthroughs, with an increasing number of fields leveraging this technology for large-scale production.

Figure 6: The Tungsten Steel Nozzle Tip/Tube

Throughout 2023, BLT, in collaboration with its team and users, has been at the forefront of accelerating the application of metal additive manufacturing technology across a broader range of components, updated scenarios, larger scales, and emerging domains. Prioritizing customer experience and feedback, BLT strives to provide better products, faster efficiency, and more cost-effective solutions through additive manufacturing technology. This commitment positions BLT as a driving force in transforming the manufacturing industry, leading the way into a new era of production in the additive manufacturing world.

Metal 3D printing tech is gaining traction in the global aerospace and other heavy industries, evolving in its application for advanced printing system development and mass production. The growing number and diversity of products, coupled with larger sizes and intricate structures, underscore the deepening integration of this technology. Overseas users, in particular, now view metal additive manufacturing as a routine method for component development and batch production. The demand for mass-production solutions has surged, with numerous users setting up production lines equipped with over 50 large-format printing systems at home and aboard.

Figure1: BLT Intelligent AM Factory of Large-format Printing System

Tackling the challenge of mass-producing metal additive manufacturing is a multifaceted endeavor, delving into technical aspects like materials, equipment, processes, and additive manufacturing design. It spans production line administration, product quality control, and safety measures. Leveraging over a decade of expertise in tailored product R&D, BLT has thoroughly understood the aerospace and other heavy industry sectors’ need for large-scale printing systems in metal additive manufacturing batch production. In 2023, BLT has achieved significant strides in advancing metal additive manufacturing machinery.

1. Platform-based large-format printing systems

In 2023, BLT unveiled platform-based solutions for large-scale additive manufacturing printing systems. Introducing the BLT-S615 (Build Dimension: 600mm×600mm×1500mm or 650mm×650mm×1300mm, W×D×H) and BLT-S815 (Build Dimension: 800mm×800mm×1500mm， W×D×H), these innovations aim to cut costs, enhance material versatility, and allow interchangeable use of consumables, powder barrels, and other auxiliary tools. With streamlined site management, users can expect improved process efficiency.

2. BLT Unveils Cutting-Edge Multi-Laser Production Machine

BLT introduced the BLT-S1500, an extraordinary ultra-large format laser machine, which has been validated by engineering applications at the TCT exhibition. The BLT-S1500 boasts a substantial build dimension of 1500mm×1500mm×1200mm (W×D×H) and is equipped with an impressive 26-laser system. In a recent development this November, BLT revealed yet another groundbreaking solution with the BLT-S1300 (26 laser) platform. The BLT-S1300 printing system offers a build dimension of 1300mm×1300mm×1400mm (W×D×H).

Addressing concerns about the quality and stability of parts in multi-laser production, BLT has diligently enhanced optical consistency, splicing accuracy, and splicing stability maintenance, and introduced flow field solutions and lens protection measures. These optimizations ensure that the larger format printing systems accommodating multiple lasers meet stringent forming requirements while delivering consistent and high-quality parts.

Figure2: BLT-3D printed Intermediate Compressor Case Printed by BLT-S1500 (26 laser, build dimension: 1500mm×1500mm×1200mm )

3. Shared powder circulation system

Large-scale printing system typically demands extensive production time, often exceeding ten days or even a month, with a substantial powder requirement. Take the BLT-S800 as an example: for a single pass during production, around 350 kilograms of titanium alloy powder is needed, requiring three hours for manual filling. In contrast, the powder supply module BLT-GF500 achieves a full powder compartment in just 45 minutes. Enhancing production efficiency is crucial, and a well-designed powder circulation system plays a pivotal role. BLT’s large format printing system comes equipped with an integrated automatic powder circulation system, facilitating automatic powder recovery, sieving, supply, and depowdering during the printing process. This closed-loop powder management system not only boosts powder turnover for continuous production but also minimizes spillage, contamination, and other quality risks, ensuring the high quality of the final products.

In addition to the self-circulation of powder in a single machine, BLT provides in-line powder circulation solutions for multiple machines, facilitating “one-to-many” powder circulation within the production line and enhancing overall line productivity.

Figure 3: BLT-S615 and its powder circulation system

Figure 4: BLT-S815 and its powder circulation system

Figure 5: BLT-S1300 and its powder circulation system,

Figure 6: BLT-S1500 and its powder circulation system

4、 Intelligent Production Line Management Solution

Drawing on over a decade of expertise in producing customized products, BLT’s product line seamlessly covers the entire manufacturing process—from design and raw materials to production, post-processing, and inspection. The BLT-MES 2.0, an intelligent production line management software accompanying BLT printing systems, represents a masterpiece that integrates accumulated manufacturing experience into a sophisticated intelligent management platform.

Figure 7: BLT-MES Interface

BLT-MES 2.0 features an IoT module that gathers data from equipment and various terminals, enabling comprehensive monitoring throughout the production line and ensuring traceability of historical data. The production planning and management function empowers users to control resources and production capacity, enhancing production line efficiency. With the production flow function, complete control over the additive manufacturing process and subsequent stages is achieved, ensuring consistency, efficiency, and accelerated delivery times while minimizing human errors and resource waste. This function truly delivers end-to-end digital manufacturing solutions to customers.

In 2023, BLT helps many Chinese space programs with comprehensive turnkey solutions for metal additive manufacturing.

In March, Dongfang Space independently developed a supporting gas generator for the “Force-85” 100-ton liquid oxygen kerosene engine, which achieved a successful first test run and assessment. The “Force 85” engine adopts a pin bolt design and is the first 100-ton level liquid oxygen kerosene pin bolt gas generator engine in China. BLT participated in developing the “Force-85” engine and printed multiple key components such as the engine body blank and pin-type gas generator. The quality and performance of these components have a significant impact on the overall performance of the engine. On March 1-2, 2023, Beijing Star Glory Space Technology Co., Ltd. completed two semi-system joint tests of the 100-ton liquid oxygen methane rocket engine “JD-2” in real media. BLT assisted the development team in printing multiple pipeline and turbopump parts for the “JD-2” liquid engine, helping customers reduce costs and increase efficiency.

In July, BLT’s Additive Manufacturing enabled the successful launch of the world’s first liquid oxygen-methane rocket. During its development, the BLT team conducted a comprehensive analysis of the service conditions for several parts, selecting materials such as superalloys and stainless steel to meet the required mechanical properties.

On November 2, Space Honor, a subsidiary of Beijing Interstellar Glory Space Technology Ltd. (i-Space), achieved a milestone in China’s commercial spaceflight with the successful flight test of the Liquid Oxygen Methane (LOM) Reusable Validation Rocket, codenamed Double Curve II (SQX-2Y). BLT played a crucial role in the production of tees, injectors, and other components for Double Curve II. The injector, featuring dozens of precision-required nozzles, utilized metal 3D printing technology for the integrated manufacturing of nozzles. The resulting parts demonstrated impeccable quality, precision, and performance, meeting the stringent requirements for spaceflight use.

Figure 8: BLT showecased the Injector at Formnext 2023

In recent years, the aerospace and other heavy industries have seen significant advancements, placing higher demands on the performance and reliability of printing systems. Parts now trend towards larger sizes, intricate structures, and seamless integration of form and function, with a preference for high-strength alloys exhibiting excellent high-temperature performance. Leveraging over a decade of expertise in customized product manufacturing, nearly ten years of honed skills in structural optimization and design, a robust technology R&D matrix, proven technologies, and dependable printing systems, BLT stands poised to offer spaceflight clients a comprehensive industrial solution. This enables them to efficiently conduct small-scale trial production and swiftly manufacture parts. BLT has also introduced a range of printing materials tailored for the aerospace and other heavy industry sectors, supporting every innovative stride in commercial aerospace and other heavy industry breakthroughs. To date, BLT has delivered more than 200 sets of large-format printing systems, rigorously tested in various aerospace and other heavy industry component engineering applications. BLT’s large-format printing systems and solutions will continue to propel the Aerospace Industry and other heavy industries into the mass-production era!

On January 11, 2024- Orienspace launched the Gravity-1 Y-1 commercial carrier rocket. The rocket delivered the Yunyao-1 No. 18-20 satellites into their predetermined orbits, Gravity-1 Y-1’s launch mission achieved complete success. Bright Laser Technologies (BLT) provided vital metal additive manufacturing (AM) support for the development of critical parts in Gravity-1 Y-1.

Why adopt Additive Manufacturing in Gravity-1 Program?

The main bundle related components of Gravity-1 Y-1 are large in size and they are all feature complex geometries that are prone to deformation. These components pose challenges in traditional manufacturing methods, such as high processing difficulty, long production cycles, and low material utilization. However, utilizing LSF technology enables the rapid production of these large structural components.

How was BLT’s Additive Manufacturing expertise implemented in the Gravity-1 Program?

BLT was involved in the development of “Gravity-1” and utilized LSF technology to produce the main bundle related components for the Orienspace. BLT’s LSF technology achieves near-net shaping of large-sized complex-shaped components, which reduces the production cycle and cost of the components, shortens the development cycle, significantly improves material utilization, and reduces manufacturing costs. After examination, it has been verified that the room temperature tensile mechanical properties of TC11 titanium alloy parts are reliable, with a tensile strength of ≥1060 MPa and a yield strength of ≥885 MPa, meeting the technical requirements and ensuring product quality. Furthermore, after the solidification process, the cost and production cycle meet the demands for mass production. BLT utilized multiple machines simultaneously printing to produce over 30 main bundle related products in batch for the client. The formed components exhibit high consistency in quality performance, meeting the stringent requirements for aerospace applications, thereby contributing to the successful launch of the rocket into space.

In recent years, aerospace components have been trending towards larger sizes, increased complexity, and integrated structural functionality. Metal 3D printing technology plays a significant role in accelerating the development and iteration of aerospace components and promoting high-quality advancements in the aerospace industry. Currently, BLT has made significant progress in SLM, LSF, and WAAM processes, successfully assisting commercial aerospace clients such as Orienspace, i-Space, and LandSpace in realizing their “space dreams.”

Nowadays, BLT has a customer base of over 30 companies in the commercial aerospace industry. We provide comprehensive support for our customers, including optimized design, technical consultation, parts development, and equipment matching. With over a decade of experience in customized product manufacturing, structural optimization design, a well-established technology R&D matrix, and proven engineering expertise, BLT’s equipment and powder products enable fast research and efficient small-batch customization of components for commercial aerospace users with complete industry support.

With the assistance of BLT, TITAN SUPER BOND successfully manufactured the first Fully 3D-printed Titanium Alloy Bicycle Frame in China, and even across Asia. Titanium alloy 3D printing has officially entered the bicycle industry, opening up limitless manufacturing possibilities for Chinese bicycle manufacturers, represented by TITAN SUPER BOND .

Figure 1: Fully 3D-printed Titanium Alloy Bicycle Frame

Why adopt Additive Manufacturing in bicycle production?

The globally renowned Chinese bicycle industry still faces challenges in the R&D and production of certain high-end critical parts. Metal 3D printing offers significant advantages in manufacturing high-difficulty complex structural parts for bicycles. With precise process control using high-quality metal 3D printing machines, it ensures stable, high-quality production of parts while maintaining dimensional accuracy within the bicycle industry’s requirements of 0.03mm. Additionally, 3D printing technology allows customized vehicle parts to be tailored according to the rider’s habits and requirements, improving riding posture and maximizing riders’ energy output. 3D-printed bicycle parts have higher strength and elongation than ordinary machined parts, resulting in better product quality, greater durability, and lightweight design.

In traditional production processes, manufacturing a bicycle involves multiple steps, including precision casting, CNC machining, wire cutting, welding, calibration, and surface treatment. These processes are intricate and time-consuming, often resulting in a production cycle of approximately 45 days from design to delivery. Metal 3D printing technology simplifies processing steps, reduces production time, and minimizes material waste. The production process of a 3D printing line is 40% simpler compared to traditional processes, resulting in a 30% reduction in production cycles and over 20% savings in production materials. This technology significantly enhances the process strength of welding-intensive areas, reduces labor intensity for technical workers, shortens working hours, and accelerates overall production capacity. Moreover, the introduction of 3D printing technology has optimized the construction process of traditional welding sites by scientifically avoiding areas with concentrated heat effects and performing circumferential lap welding in standard and open pipe sections. This strategic “encircling and supporting” approach to frame welding greatly reduces the technical difficulty of manual argon arc welding and provides possibilities for future robotic automated welding.

How was BLT implemented in the TITAN SUPER BOND Bicycle Production Program?

In 2022, TITAN SUPER BOND introduced two Laser-Powder Bed Fusion metal 3D printing machines, BLT-A320, from BLT. With the comprehensive support of BLT’s targeted full set of solutions, TITAN SUPER BOND gradually upgraded its R&D and production capabilities in metal 3D printing, empowering the high-end bicycle market. Since the collaboration began, both parties have successfully addressed challenges related to deformation control of complex-shaped parts and weight reduction.

Figure 2: Two BLT-A320 Machines in the TITAN SUPER BOND Factory

For complex-shaped parts with a wall thickness of only 0.9mm, controlling deformation is the biggest challenge during the printing process. Based on the BLT-A320 machine, TITAN SUPER BOND and BLT have developed a comprehensive solution encompassing detailed production processes such as part design, part support, and lattice control. The printed parts successfully passed the international standard ISO 4210 dynamic fatigue strength test. Additionally, the two parties have collaborated to develop support solutions for large-scale parts and new products, optimization schemes for part lightweight structures, validation of the difficulties in polishing processes for varying layer thicknesses, stability testing for fully nested printing, and assessment of surface roughness for assembly, thus ensuring ample technical readiness for high-quality mass production and customized services for bicycle parts.

The BLT-A320 machine is utilized to produce high-precision titanium alloy bicycle handlebars, and head tubes, characterized by their lightweight, high strength, corrosion resistance, and long service life. The lightweight design effectively reduces the weight of bicycle dropouts and YOKE, thereby reducing the overall vehicle weight and enhancing the vehicle’s speed, which aids riders in minimizing physical exertion during long-distance cycling. The high-strength titanium alloy frame facilitates efficient power transfer and enhances maneuverability, while providing exceptional elasticity, surpassing steel by 30%, and offering exceptional shock absorption capabilities. Titanium alloy parts are resistant to corrosion from acid rain, UV rays, humidity, and other environmental factors. Their metal surfaces remain impervious to dents and rust even after prolonged exposure to air. Meanwhile, 3D-printed titanium alloy bicycles exhibit superior strength and extended lifespan compared to conventional titanium alloy bicycles, essentially achieving permanent damage-free usage.

Figure 3: Metal 3D-printed Bicycle Parts

Figure 4: Titanium Alloy Frame

BLT-A320 boasts a maximum build dimension of 250mm×250mm×300mm (W×D×H). This machine achieves a near 100% density for mold printing and provides polishing performance up to the A0 level. In addition to high-quality mold products, the BLT-A320 can also print various conventional materials such as titanium alloy, aluminum alloy, superalloy, and high strength steel, meeting the printing needs of other industries. Equipped with two optics configurations, the BLT-A320 significantly enhances the efficiency of part formation. Furthermore, the machine not only introduces a nitrogen printing solution and long-life filtration system but also offers optional features such as grafting printing, helping customers reduce operating costs, and facilitating convenient machine operation.

The 3D-printed Titanium Alloy Bicycle Frame demonstrates great value as a brand-new exploration and application of 3D printing technology beyond high-end manufacturing sectors such as aerospace and medical devices. BLT will engage in “cross-industry collaboration” with more industries, exploring new application directions, injecting technological energy into more partners, and unlocking endless possibilities for industry development.

About BLT

BLT (Bright Laser Technologies) [Stock Code: 688333.SH], is a global leader in providing comprehensive turnkey solutions for metal additive manufacturing and remanufacturing. BLT has developed a mature metal AM ecosystem with a strong focus on industrial metal 3D printers, metal powders, printing services, innovative software, and additive consulting. Drawing on years of expertise in metal additive manufacturing technology, BLT caters to a wide range of industries including aerospace, energy, medical dentistry, industrial tooling, automotive manufacturing and more. Through continuous innovation, the company strives to meet the evolving needs of its customers.