At TCT 2021, BLT launched BLT-S800, a 10-laser system designed for rotating aero-engine components. Building on years of stable operation with over 40 units of BLT-S800 at BLT’s Xi’an intelligent manufacturing factory for consecutive years, BLT introduced BLT-S815 in 2023, a platform-based solution for large-size, long-shaft parts with an increased build height of 1500mm. Later that year, BLT unveiled a new 20-laser configuration of BLT-S800 at TCT. After further R&D and optimization, BLT unveiled BLT-S825 at the 15th Airshow China, a meter-scale 24-laser system for integrated manufacturing of ultra-high parts.
BLT-S825 offers a build dimension of 850mm × 850mm × 2500mm (W×D×H) with a net build height exceeding 2.5m, meeting the demand for integrated manufacturing of ultra-high parts. BLT-S825 has undergone engineering application testing, and its latest design case for engineering applications, the hanging bracket, was also on display at BLT’s booth at the exhibition.
The hanging bracket is a large-size frame component that was previously manufactured by casting or welding. As the size of the component increases, the difficulty and cost of using tooling machines and molds for integrated tooling also increase significantly. BLT optimized the structural design of the hanging bracket, adopting a large number of hollowed-out structures and selecting BLT-TA15 titanium alloy material with low weight and high strength. This greatly reduced the part weight while ensuring functionality and strength, achieving a large-span connection function. The part measures 500mm×200mm×2350mm (W×D×H) and was integrally formed using BLT-S825, demonstrating the process stability of the system.
01 24-Laser Configuration for Higher Efficiency
BLT-S825 is configured with 24 lasers, equivalent to arranging 6 lasers on a 400mm format machine. It supports printing with a large layer thickness of 100μm, achieving a maximum forming efficiency of up to 870cm3/h for more efficient production.
BLT-S825 is equipped with BLT-BP which enables rapid, one-pass efficient slicing of ultra-high parts, reducing the slicing time and preparation time before printing. For instance, a 2.4-meter-high part with 32.56GB of slicing data requires only 1.5 hours for slicing using BLT-S825.
BLT-S825 employs single-recoater double-direction variable-speed powder spreading technology, solving the issue of time-consuming leveling with dual recoaters in large-format systems. During printing, it intelligently adjusts powder spreading speed based on part geometry, implementing variable-speed powder spreading, which is 30% more efficient per layer than constant-speed powder spreading. Consequently, forming this part with BLT-S825 takes only nine days.
02 Mature Solutions Upgraded for Quality Assurance
In 2023, BLT showcased the 20-laser BLT-S800 with air blowing on top at TCT and showcased synchronous laser emission and printing of the 20-laser BLT-S800 at TCT 2024. At the 15th Airshow China, BLT also presented the 16-laser BLT-S600 which demonstrated high-efficiency printing on site.
BLT-S825 preserves its mature optical and air-blowing solutions, supporting efficient forming with simultaneous emission of four rows of lasers. The system boasts excellent airtightness, with working gas consumption below 10L/min. Its air-blowing solution provides a highly uniform air field, keeping the lens clean for over 700 hours and ensuring more stable forming. For example, BLT-S825 can print multiple hanging brackets in one batch, with high consistency in formed parts and deviations within 5% for various performance indicators across different regions.
BLT-S825 boasts an ultra-high build height and a depth-to-diameter ratio of nearly 3:1. Traditional methods of assembled build cylinders involve a high risk of deformation, potentially causing loss of precision in the build platform and resulting in dimensional deviations in parts. BLT optimized the structure of the build cylinder, reinforcing it while significantly reducing its weight. The optimized cylinder, integrally formed with 3D printing, ensures the strength and manufacturing consistency. Additionally, BLT-S825 extensively incorporates metal 3D-printed parts with optimized designs, enhancing its integration and durability.
Since 2017, BLT has accumulated design expertise in ultra-high Z-axis systems, successively developing systems with build heights up to 1.5m, including BLT-S515, BLT-S615, BLT-S815, and BLT-S1000. Based on the long-term operational experience of over 200 units with high build heights, BLT designed and developed systems with a build height of up to 2.5 meters.
BLT-S825 incorporates BLT’s extensive experience in the build platform, utilizing dual-axis servo drives with high-precision grating scales for closed-loop control of the build platform. While ensuring ultra-high build heights and operational precision, BLT’s machine & system development team has managed to control the overall height of the system, with its external height reaching only 5.5 meters in height, meeting the installation requirements for standard workshops.
BLT-S825 is equipped with a quality monitoring system, including BLT-Powder Spreading Detection, BLT-3D Reconstruction, and BLT-Video Monitoring, enabling real-time key parameter monitoring, image capture, data analysis, and video monitoring for process control and quality traceability.
03 Advanced Configuration for Continuous Production
BLT-S825 is equipped with a parallel long-life filtration system. During the printing process, when the current working filter element meets the conditions for dust removal, it can automatically perform backflushing and then switch to another set of filter elements to continue printing, achieving uninterrupted operation. Additionally, the ash bin is designed with safety features, allowing for wet treatment under an inert atmosphere, enabling safe replacement of the ash bin without interrupting the operation, and effectively avoiding downtime risks from filter element backflushing or ash bin treatment. This meets the continuous production demands of large-format systems, enhancing efficiency and reducing costs.
BLT-S825 offers an integrated or modular powder circulation system. The integrated powder circulation system supports automatic powder recycling, sieving, and supplying within a single unit during printing, enabling more efficient resource allocation and reducing costs and energy consumption. The modular system enables flexible, one-to-many configurations to meet diverse production needs.
04 Redundant Design for Enhanced Safety
BLT-S825 adopts a safety redundancy design for the entire system, establishing a complete safety protection system. It features explosion-proof design, complemented by redundant settings for oxygen content detection systems and pressure sensors, enabling comprehensive monitoring of oxygen content, pressure, and temperature. The system automatically relieves pressure when overpressure is detected. Submodules such as the filter, powder circulation system, and transfer station are all equipped with independent oxygen content, pressure, and temperature detection, ensuring the safe operation of the entire system. BLT-S825 is equipped with argon gas purging safety interlock mechanism to prevent accidental oxygen intake and argon leakage, guaranteeing safe production while ensuring personnel operation safety.
BLT-S825 is equipped with an airtight transfer station. When connected to BLT-WL400 or BLT-XH300, it allows safe depowdering and removal of parts with a full height of 2.5m under inert atmosphere protection through the supporting multi-station and glovebox. This ensures human-powder isolation as well as efficient powder recycling under inert gas protection.
In its pursuit to push the boundaries of aerospace manufacturing, BLT has diligently analyzed the innovative development needs of the aerospace industry and provided dedicated support and service. BLT-S825 has emerged as a result of this commitment. We invite you to visit us at booth H5B12 at Airshow China 2024 to experience the engineering innovations of BLT-S825 and witness its outstanding capabilities in producing large, superior, specialized, and precision aerospace components.
