Velo3D applied its Rapid Production Solutions to manufacture Inconel 718 microtube heat exchanger headers for Intergalactic's commercial aircraft cabin air system, achieving a design-to-part cycle in under three weeks. These components will undergo system-level testing on aggressive timelines, highlighting RPS's ability to deliver production-ready hardware without redesign or extended development.

The Sapphire XC platform leverages a non-contact recoater and advanced parameter sets to print large-radius geometries and low-angle transitions with minimal internal supports. By using Velo3D's standard Inconel 718 parameters, the company eliminated part-specific calibration, ensuring repeatable quality and reducing time to first article with large-format metal additive manufacturing.

Velo3D's production Technical Data Package establishes a digital inventory model, enabling identical parts to be manufactured across any validated Sapphire or Sapphire XC system. This distributed, flexible supply chain approach supports long-term program scalability and reduces dependency on machine-specific development, laying groundwork for volume production of mission-critical aerospace components.