Velo3D develops process for Additive Manufacturing of Al F357

May 6, 2020

Additively manufactured aluminium F357 part produced on Velo3D’s Sapphire metal AM machine (Courtesy Velo3D)

Velo3D, Campbell, California, USA, has announced the commercial release of a manufacturing process for additively manufactured parts in aluminium F357 on its Sapphire® metal Additive Manufacturing system for thin-walled heat transfer applications.

According to the company, F357, a foundry-grade aluminium alloy, is suitable for the Laser Powder Bed Fusion (L-PBF) process and enables the metal Additive Manufacturing of parts that have traditionally only been manufactured using casting practices. There are other aluminium alloys that are more commonly used in metal AM, such as AlSi10Mg, but aluminium F357 can be anodised and shares characteristics with A356, a widely-used casting alloy.

“Aluminium F357 has already been certified for mission-critical applications – unlike some exotic alloys – so it was a logical addition to our materials portfolio,” explained Benny Buller, Founder and CEO of Velo3D. “We will continue to add more compatible materials that enable customers to print parts they couldn’t before, yet with even better material properties than traditional manufacturing.”

The manufacturing process was developed jointly with PWR, a global supplier of advanced cooling solutions to Formula 1, NASCAR and other racing series, along with the automotive, military and aerospace industries. Matthew Bryson, General Manager for PWR, commented, “We chose aluminium F357 due to its ideal material properties to suit thermal performance, machining and weldability.”

“Our ability to print free-form and lightweight structures for heat transfer applications with our Sapphire system from Velo3D will further enhance performance and packaging optimization opportunities for our product range and provide significant value to our customers,” he explained.

Further to this new F357 manufacturing process, Velo3D’s patented SupportFree AM process eliminates the need for support structures for the production of complex passageways, steep overhangs and low angles. Coupled with its non-contact recoater, the company explains that its Additive Manufacturing process can produce the ultra-thin wall structures and high aspect ratios that are essential for a variety of flight-critical applications.

In the latest issue of Metal AM magazine

Download PDF

Extensive AM industry news coverage, as well as the following exclusive deep-dive articles:

  • Metal powders in Additive Manufacturing: An exploration of sustainable production, usage and recycling
  • Inside Wayland Additive: How innovation in electron beam PBF is opening new markets for AM
  • An end-to-end production case study: Leveraging data-driven machine learning and autonomous process control in AM
  • Consolidation, competition, and the cost of certification: Insight from New York’s AM Strategies 2024
  • Scandium’s impact on the Additive Manufacturing of aluminium alloys
  • AM for medical implants: An analysis of the impact of powder reuse in Powder Bed Fusion

The world of metal AM to your inbox

Don't miss any new issue of Metal AM magazine, and get the latest industry news. Sign up to our twice weekly newsletter.

Sign up

Discover our magazine archive…

The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:

  • Reports on visits to leading metal AM part manufacturers and industry suppliers
  • Articles on technology and application trends
  • Information on materials developments
  • Reviews of key technical presentations from the international conference circuit
  • International industry news

All past issues are available to download as free PDFs or view in your browser.

Browse the archive

Looking for AM machines, metal powders or part manufacturing services?

Discover suppliers of these and more in our comprehensive advertisers’ index and buyer’s guide, available in the back of Metal AM magazine.

  • AM machines
  • Process monitoring & calibration
  • Heat treatment & sintering
  • HIP systems & services
  • Pre- & post-processing technology
  • Powders, powder production and analysis
  • Part manufacturers
  • Consulting, training & market data
View online
Share via
Copy link
Powered by Social Snap