Breakthrough in Net Forming Height Beyond 2.5 Meters! Equipped with 24 Lasers, BLT Unveils the Ultra-Large Metal 3D Printer BLT-S825

On November 12, 2024, BLT launched the BLT-S825 at the 15th China Airshow, advancing the manufacturing of ultra-large components. With dimensions of 850 mm × 850 mm × 2500 mm (W × D × H), this revolutionary device achieves a net forming height exceeding 2.5 meters, meeting the requirements for integrated production of oversized components. 

The BLT-S825 passed rigorous engineering application tests, featuring a groundbreaking design concept demonstrated through the “Suspension Frame.” Traditionally manufactured using casting and welding methods, the increasing size of such components has made integrated die-casting impractical due to higher costs and complexities.  BLT optimized the suspension frame's structural design, employing lightweight, high-strength BLT-TA15 titanium alloy. This reduced its weight significantly while maintaining its functional integrity and strength. The frame, measuring 500 mm × 200 mm × 2350 mm, was seamlessly formed using the BLT-S825, showcasing the equipment’s stability. 

△Hangings with a height exceeding 2 meters

Efficiency Through 24-Laser Configuration 

Outfitted with 24 lasers—comparable to six lasers on a 400 mm machine—the BLT-S825 supports large-layer thickness printing at up to 100 µm. The device achieves an impressive forming efficiency of 870 cm³/h. 

Its advanced BLT-BP system streamlines slicing for oversized parts, drastically cutting pre-print preparation time. For instance, processing data for a 2.4-meter part (32.56 GB) took just 1.5 hours. 

The BLT-S825 employs a single scraper with dual-direction variable-speed powder spreading. This innovative method resolves leveling challenges in large-format devices, increasing powder-laying efficiency by nearly 30% compared to fixed-speed techniques. A 2.4-meter part, produced in only nine days, exemplifies its efficiency. 

Evolved Solutions for Enhanced Quality 

BLT respectively exhibited the 20-laser BLT-S800 system with top - blowing air at the TCT in 2023. In 2024, during the TCT, it showcased the on - site simultaneous light-emitting printing of 20-laser BLT-S800. At the 15th China International Aviation & Aerospace Exhibition, it also presented the top-light-emitting with blowing air solution of 16-laser BLT-S600, enabling highly efficient on-site printing.

The BLT - S825 inherits BLT's sophisticated optical and top - blowing air schemes, facilitating efficient forming with four rows of lights emitting simultaneously. The BLT - S825 enjoys excellent airtightness, with the working air intake consumption lower than 10L/min. The top - blowing air solution equipped in the equipment features high air - field uniformity. The lens can maintain cleanliness for over 700 hours, thus ensuring exceptional stability. For multi-part production, such as suspension frames, the BLT-S825 delivers high consistency, with performance deviations of less than 5% across various regions.

The BLT - S825 has an extraordinarily high forming height, with the depth-to-diameter ratio approaching 3:1. The forming cylinders produced by the traditional split-cylinder method are highly prone to deformation risks. During the forming process, this is more likely to result in the loss of the precision of the forming platform, thereby causing the machining dimensions of parts to exceed the tolerance. BLT has conducted a structural optimization design on the forming cylinder. While strengthening the cylinder body, it has achieved a substantial weight reduction of the cylinder. The optimized cylinder is integrally formed through 3D printing technology, guaranteeing the strength and manufacturing consistency of the forming cylinder. Additionally, the widely optimized metal 3D printing equipment components within the BLT-S825 have enhanced the equipment's integration and durability.

Since 2017, BLT has been amassing design expertise in the ultra - high Z - axis, successively developing apparatuses such as BLT - S515, BLT - S615, BLT - S815, and BLT - S1000, all of which possess a forming height of up to 1.5 meters. Grounded on the long - term operational experiences of over 200 high - forming - height devices and through ceaseless iteration, BLT designed and developed equipment with an astounding forming height of 2.5 meters in 2023.

The BLT - S825 device inherits the forming platform design know - how that BLT has accrued, refined, and iterated over numerous years. It employs biaxial servo drives in conjunction with high - precision grating scales to actualize closed - loop control of the forming platform. While safeguarding ultra - high forming dimensions and operational precision, the R & D team of BLT equipment has managed to control the overall height of the equipment. With a height of merely 5.5 meters in its external dimensions, the equipment meets the installation requisites of ordinary factory buildings.

The BLT - S825 is furnished with a top - quality quality monitoring system, encompassing BLT - powder - spreading detection, BLT - three - dimensional reconstruction, and BLT - video monitoring. This system enables the monitoring of crucial parameters, image acquisition, data analysis, and full - process video surveillance during the printing process, thereby facilitating process intervention and post - event quality traceability.

Mature Configurations for Seamless Production 

The BLT-S825 features a parallel long-life filtration system, enabling uninterrupted operations by automatically cleaning and switching filter cartridges. Safety mechanisms, like inert-atmosphere processing for waste buckets, further enhance continuous production without compromising operator safety. 

The device supports both integrated and modular powder recycling systems. The integrated approach automates powder recovery, sieving, and supply, maximizing resource efficiency. Conversely, the modular system offers flexible multi-machine configurations for varied production demands. 

△Integrated Powder Recirculation System

△Split-Type Powder Recirculation System

Safety and Redundancy for Reliable Operations 

The BLT-S825 adopts a comprehensive safety design, including explosion-proof systems and redundant sensors for oxygen content, pressure, and temperature. In case of overpressure, the system ensures automatic, secure relief. Each module—filter, powder circulation, and retrieval chamber—operates with independent monitoring, ensuring system-wide safety.  A sealed retrieval chamber further enables safe part handling under an inert atmosphere, facilitating efficient powder recovery while maintaining operator safety. 

Conclusion 

The BLT-S825 reflects BLT’s expertise in addressing aerospace and advanced manufacturing needs. This state-of-the-art machine sets new standards for large-scale, high-precision, and integrated 3D printing.

Visitors are invited to explore its groundbreaking capabilities at booth H5B12 during the China Airshow. Experience firsthand the engineering marvels that define BLT’s latest technological strides.