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BLT (Bright Laser Technologies) showcases its turnkey solutions for metal additive manufacturing at Formnext 2023. BLT introduces the industrial metal 3D printing machine BLT-S400, and its automatic powder circulation system. Furthermore, BLT demonstrates its exceptional applications across various industries and introduce its self-developed materials.

Figure 1: BLT Booth at Formnext 2023 (1)

Figure 2: BLT Booth at Formnext 2023 (2)

Figure 2: BLT Booth at Formnext 2023 (3)

Global Launch of the BLT-S400 Machine

The BLT-S400’s three-laser configuration makes it suitable for high-volume production of industrial parts. Customers with high-volume production need to experience a relatively high time cost when utilizing Metal 3D printing. BLT’s focus is to find ways of reducing delivery time and minimizing labor costs while ensuring the utmost quality of the production part. With the introduction of the BLT-S400, these concerns are effectively alleviated for our clients.

With its configuration of 3 lasers, the BLT-S400 boosts production efficiency, making it an ideal choice for mass production of small and middle-size components. The global official launch date of BLT-S400 is November 7.

 Figure 4: BLT-S400

Global Launch of BLT-Automatic Powder Circulation System

The BLT-S400’s new Automatic Powder Circulation System ensures the safe transfer, recovery, sieving, and reuse of metal powders within an on-site test laboratory. Thus, the system facilitates the seamless and secure transfer of large volumes of 3D printing powders from containers to multiple machines, eliminating the risk of spillage contamination, explosion, and contact with workers. It’s important to mention that the BLT-automatic powder circulation system can support multiple 3D printing machines, offering a more cost-effective investment option that can significantly enhance production efficiency.

Figure 5:  BLT-S400 and its Powder Circulation System

Diverse Types of Innovative 3D Printed Parts Across Various Fields

BLT brings dozens of exhibits for aviation, aerospace, mold, medical, electronics, and other applications. Meanwhile, the latest exhibits are unveiled for the first time on-site.

One of the most attractive exhibits is the Intermediate Compressor Cas, which is a crucial load-bearing component for aviation engines. This part is made from titanium alloy material, with external dimensions of Φ1350mm×205mm, and a wall thickness of about 2mm. The design features a self-forming reinforcing rib structure on the surface to ensure strength while reducing weight. The part is an example of the BLT-S1500 (a newly released metal 3D printer that features 26 lasers and a build volume of 1500mm × 1500mm × 1200mm (W × D × H).)’s combination of production capacity and build size, which is geared towards the manufacture of singular large and complex parts, and rapid mass production of small and medium-sized parts.

Figure 6: Intermediate Compressor Case (1)

Figure 7: Intermediate Compressor Case (2)

Figure 8: Intermediate Compressor Case

BLT also shows a thrust chamber injector for Beijing Star Glory Space Science & Technology Company’s (i-Space) 100-ton liquid oxygen methane engine, known as “JD-2.” The JD-2 achieved a significant milestone by successfully completing two semi-system joint tests under real operating conditions. which completes real medium semi-system joint tests. The injector includes multiple long and short fuel nozzles with intricate features, which were produced on the BLT-S600 using BLT’s in-house developed superalloy BLT-Inconel 718. Its size is φ524mm×190mm and it weighs 56.7 kg. Compared to traditional processes, using 3D printing technology for processing provides high integration, lower process difficulty, shorter production cycles, and lower cost. (Cost can be reduced by approximately 30%; the traditional process for the injector involves over 300 parts and takes 8 months to manufacture, while 3D printing can be completed in 3-4 months)

Figure 9:  Thrust Chamber Injector 

At this exhibition, BLT also showcases 3D-printed components in industries such as molds, energy, and shoe molds, demonstrating BLT’s new material development and support-free solutions.

Full Launches of BLT’s Self-developed BLTM powders

BLT has over 10 powder production lines with more than 400 tons of yearly capacity, mainly focusing on producing Titanium and Inconel Alloy family powders. It can help customers achieve the whole process service of powder trial production, small batch preparation, verification of printing application, mass production, and so on. Additionally, BLT provides customized services to meet the specific requirements of our users for various powder products. At Formnext, BLT brings powders including pure titanium and titanium alloy, as well as the exhibits made of the above materials.

Figure 10:  BLT Powder

Enhancing Production Efficiency through In-House Software: BLT-BP and BLT-MES

BLT-BP is a dedicated 3D printing slicing software tool for BLT AM systems. With an intuitive workflow and easy navigation, it has significantly improved the slicing efficiency for parts that are numerous, large in size, and have complex structures. Even for parts with a substantial 25G data volume, the required profiling time is merely 30 minutes. Furthermore, the BLT-BP has a dynamic powder laying strategy that adapts powder fusion speed to the part contour, enabling multi-stage automatic speed adjustments. This approach ensures both quality and efficiency. Typical parts experience a notable 30% improvement in single-layer efficiency compared to the conventional method.

Besides BLT-BP，BLT proudly integrates its advanced series of printing machines and systems (available for all BLT 20 models of AM machines) with the cutting-edge BLT-MES 2.0, a proprietary, self-developed intelligent production line management system. Distinguished as an industry trailblazer, BLT-MES 2.0 represents a groundbreaking achievement by establishing seamless data IoT connectivity between the planning and execution tiers within the additive manufacturing landscape. This visionary system offers comprehensive end-to-end digital manufacturing solutions, encompassing product management, project planning, intelligent scheduling, manufacturing execution, data IoT integration, statistical dashboards, online reporting, and more. In doing so, BLT-MES 2.0 spearheads the dawn of a ‘mass-production era’ in metal additive manufacturing, bestowing unparalleled digital empowerment upon this dynamic sector.

Figure 11:  BLT-MES and BLT-BP

The BLT-S400 industrial metal additive manufacturing machine, its automated powder circulation system, and its powder family and in-house software are showcased at the prestigious Formnext exhibition in Germany. BLT is pleased to announce the forthcoming availability of these products in international markets. For comprehensive information, please get in touch with our dedicated team of sales engineers or visit our product page at https://www.xa-blt.com/en/

Figure 12:  BLT Team at Formnext 2023

China – September 12 – Bright Laser Technologies (BLT), a global leader in additive manufacturing, has just unveiled the BLT-S800 metal 3D printer, featuring an extra-large build volume (800mm x 800mm x 600mm) and configuring with 20 fiber lasers to shorten the part delivery cycle time and enable rapid research and manufacturing for customers.

BLT-S800 can work with titanium alloy, aluminum alloy, high-temperature alloy, stainless steel, high-strength steel, and tool steel. Its applications span across various industries, including aviation, aerospace, engine, medical, automotive, electronics, mold, and research institutes.

“By investing a decade in large format and multi-laser printing, the BLT-S800 has excelled in system stability. Currently, we have deployed dozens of BLT-S800, 20-laser printers in our customers’ factories, and their reliability and usability have been tested in the market,” said Eliza Duan, head of International Business Department, BLT.

Boosting Production with 20 Synchronized Lasers

Within the same floor space， increasing the number of optical paths directly increases production capacity and plant efficiency without the need for extra equipment, additional factory space, or more operating personnel.

Advancements in Wind Field Optimization

In the realm of wind field optimization, innovative solutions have been implemented to support the synchronized operation of 20 lasers. These innovations effectively disperse any black smoke and splatter generated during multi-laser printing, ensuring parts quality. Simultaneously, they ensure the optical lenses remain clean, guaranteeing uninterrupted printing processes.

Enhanced Serial Production with the Powder Circulation System.

Efficient powder recovery plays a pivotal role in mass production workflows. The BLT-S800 introduces an innovative powder circulation system designed to safely transfer, recover, sieve, and recycle metal powders in an on-site test lab. This system simplifies and secures the movement of large volumes of 3D printing powders from containers to multiple machines, effectively eliminating the risks associated with spillage, contamination, explosions, or contact with personnel. This system empowers manufacturers to meet their serial production needs while achieving substantial cost savings in their operational endeavors.

Enhancing Production Efficiency through In-House Software

Configured with BLT-BP, the BLT-S800 offers the capability for streamlined profiling of large-sized parts. This reduces the time spent on profiling and preparation and enhances efficiency during the printing process. Even for parts with a substantial 25G data volume, the required profiling time is merely 30 minutes.

Furthermore, the BLT-BP on the BLT-S800 has a dynamic powder laying strategy that adapts powder fusion speed to the part contour, enabling multi-stage automatic speed adjustments. This approach ensures both quality and efficiency. Typical parts experience a notable 30% improvement in single-layer efficiency compared to the conventional method.

Know more about us: https://www.xa-blt.com/en/

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.

For more information about BLT [Stock Code: 688333.SH], please visit our website: https://www.xa-blt.com/en/ or send us email: international@xa-blt.com

BLT focuses on the forefront of engineering and tackles complex interdisciplinary problems, offering model evaluation and models for customers.

Leveraging additive manufacturing technology, extensive research and practical applications have been conducted in the following areas:

· Design for additive manufacturing (AM)
· Lightweight and integrated design
· Stress control design for AM parts
· Function-first Design
· Design for cost control and construction specifications
· Assessment of typical characteristics maturity and risk identification

Selective Laser Melting (SLM):
Selective laser melting (SLM) is a metal additive manufacturing (AM) technology that uses a bed of powder with a source of heat to create metal parts.

Laser Solid Forming (LSF):
Laser solid forming (LSF) is a typical laser direct energy deposition additive manufacturing technology based on the powder feeding method with a high deposition rate.

Wire Arc Additive Manufacturing (WAAM):
Wire arc additive manufacturing (WAAM) is a wire-based DED approach that uses an electrical arc as a source of fusion to melt the wire feedstock and deposit a part preform, layer by layer.

The BLT Intelligent Manufacturing Factory is equipped with 380 sets of machines and systems, with nearly half of them being large-format systems. The build dimensions of the large-format systems range from 400mm to 1500mm, while the build dimensions of the small and medium-format machines and systems range from 160mm to 400mm. Machines and systems of all sizes are capable of meeting the manufacturing requirements for various aerospace parts.

Testing Service

The BLT Testing Center provides a comprehensive range of testing services, including:

· Chemical composition analysis
· Mechanical properties testing
· Physical properties testing
· Microstructure analysis of metal materials
· Geometric quantity testing
· Non-destructive testing of metal parts
· Other related projects

BLT has successively passed the quality system certification of ISO 9001 (2015), AS 9100D/EN 9100(2018).

BLT has passed the ISO 14001 environmental management system certification(2015) and ISO 45001 occupational health and safety management system certification(2018).

Furthermore, BLT has achieved four Nadcap certifications, and the testing center has been approved as a national CNAS laboratory.

Established in 2018, the Xi’an Bright Laser Technologies Co., Ltd. Testing Center is an authorized testing institution under BLT Company, responsible for conducting multiple testing tasks for the company’s products.

How can BLT propel commercial aerospace to new heights? 

Since 2020, the Chinese commercial aerospace industry has entered a new stage of development with clearer business models and market trends. Chinese authoritative media pointed out that, after recent years of development, China’s aerospace industry foundation is further consolidated with continuous expansion of the industrial chain and improved capabilities for independent innovation.

Metal 3D printing technology possesses inherent advantages in processing large-sized, structurally complex, and high-temperature-resistant components for commercial aerospace. By designing components based on the principle of the additive manufacturing process, aerospace designers can achieve integrated optimization and functional design of components, meeting the lightweight requirements of spacecraft. This technology enables rapid production of parts while ensuring their quality, leading to shortened delivery cycles and accelerated R&D iterations. Furthermore, metal 3D printing technology also offers significant advantages in terms of batch production and cost reduction.

Reusable Liquid Oxygen-Methane Validation Rocket SQX-2Y 

On November 2, 2023, Beijing Interstellar Glory Space Technology Co., Ltd. (i-Space) Reusable Liquid Oxygen-Methane Validation Rocket SQX-2Y’s launch mission achieved complete success. This mission marks the first-ever full-scale vertical takeoff and landing, as well as reusable rocket tests of a liquid rocket first-stage in China. It is a significant breakthrough in reusable carrier rocket technology for Chinese commercial aerospace. BLT has assisted clients in developing critical components for multiple engines, effectively reducing production cycles, saving costs, accelerating product iterations, and enhancing R&D efficiency.

The world’s first Liquid Oxygen-Methane Rocket successfully launched into orbit

On July 12,2023, the Landspace ZQ-2 Y2 successfully entered the designated orbit. The launch mission achieved complete success. ZQ-2 has become the world’s first successful liquid oxygen-methane rocket to achieve orbit, marking a significant breakthrough for China’s carrier rockets in the application of new low-cost liquid propellants. It fills the gap in the domestic liquid rocket spectrum and brings about transformative changes in the commercial rocket launch market. BLT has provided comprehensive metal additive manufacturing technology support for the development of key components in ZQ-2 Y2.

12U high-resolution ground remote sensing satellite

On May 10, 2023, China’s Long March-7 Y7 carrier rocket, developed by the China Academy of Launch Vehicle Technology, successfully launched the Tianzhou-6 cargo spacecraft into its designated orbit. BLT is responsible for the structural optimization design and 3D printing production of the satellite deployer frame.

China’s first hundreds-ton-class liquid oxygen kerosene pin-type gas generator engine

In March 2023, the self-developed gas generator for the “Yuanli-85” hundreds-ton-class liquid oxygen kerosene engine by Orienspace was successfully tested for the first time. BLT has participated in the development of the “Yuanli-85” engine and 3D printed several key components such as the engine body blanks and pintle-type gas generator. The quality and performance of the final formed parts met the requirements for the “Yuanli-85” engine.

Hundreds-ton liquid oxygen methane engine

From March 1st to 2nd, 2023, the i-Space liquid oxygen methane engine “JD-2” successfully completed two semi-system joint tests with real media. BLT assisted the development team in printing multiple Piping and Turbine Pump components for the “JD-2” liquid engine, helping customers reduce costs and increase efficiency. The “JD-2” Injector (rocket engine thrust component) also made its debut at the 2023 Formnext Germany Exhibition, attracting the attention of many customers.

Currently, 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.

BLT provides equipment and components for commercial aerospace R&D, including models such as BLT-S310/S320, BLT-S400, BLT-S450, BLT-S510/S515, BLT-S600, BLT-S615, BLT-S800, BLT-S815, BLT-S1300, and BLT-S1500. Our machines and systems can be used for large and medium-sized component assembly, small-batch production of large components, and rapid mass production of small-sized parts.

The commercial aerospace industry has vast prospects for development. Not only will there be continuous advancements in satellite and rocket development, but also emerging areas such as “space products” and “commercialization of space technology” are gradually evolving. Moving forward, commercial aerospace can also facilitate the transfer of aerospace technology to the civilian market. The broad development prospects also place higher requirements on accelerating technological R&D iteration and achieving low-cost, high-quality production in the commercial aerospace sector.

Metal 3D printing technology has gradually become a common means of component development and mass production due to its advantages. BLT is involved in multiple commercial aerospace projects that have entered the mass production stage. BLT will assess the needs of commercial aerospace customers and continuously enhance its market competitiveness by optimizing design, technical and R&D support, equipment capabilities and stability, product delivery quality, cycle, and final cost. Furthermore, we will also deepen our cooperation with more commercial aerospace users.

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.

BLT focuses on the forefront of engineering and tackles complex interdisciplinary problems, offering model evaluation and models for customers.