How BLT Uses Metal 3D Printing to Manufacture 3D Printers

△ Mainframe of the BLT-S400 Series Displayed at the 2025 TCT Asia Exhibition

In recent years, the adoption of metal 3D printing in industrial settings has steadily expanded—from research and development to large-scale production. Metal additive manufacturing is no longer merely a lifeline for solving technical challenges; it has become a critical enabler for product innovation, quality enhancement, and cost reduction. Mastery and deep integration of metal 3D printing technology are emerging as key differentiators for manufacturing enterprises, gradually turning the vision of the "era of mass production" into reality.

For years, BLT has leveraged its comprehensive expertise in design, materials, processes, and equipment manufacturing to build a complete technological ecosystem. By aligning capabilities across these domains, the company has relentlessly promoted the industrial application of metal 3D printing, offering a path that balances technical advancement with economic feasibility for countless factories.

As of now, a variety of functional parts, joints, and support structures—more than a dozen in total—within different models of BLT metal 3D printers have been designed and fabricated using BLT’s own additive manufacturing systems. These components are embedded in key subsystems such as the Z-axis, forming chamber, airflow, and water-cooling paths. At TCT Asia 2025, BLT showcased a selection of these innovative parts.

01 Reimagining Component Design – Precision Engineering for Consistency and Reliability

Traditionally, industrial machinery components follow standardized designs and specifications. Developing higher-quality or more customized products often requires extended R&D cycles. However, metal 3D printing enables the integrated formation of complex geometries, significantly enhancing both performance and quality.

Take the forming cylinder as an example. Conventionally, it is assembled from multiple parts, which compromises strength and thermal stability. BLT now manufactures the entire forming cylinder in one piece using the BLT-W series (WAAM process), reinforcing localized structures and enhancing printing reliability and consistency in mass production.

△ Forming Cylinder Produced by the BLT-W Series Equipment at the 2025 TCT Asia Exhibition

In the powder spreading process, the metered powder feeding system is a core module ensuring consistent print quality. The base of the powder dropper supports the rotation of the powder shaft and enables precise powder delivery. Traditionally fabricated via welding and assembly, these components often suffer from alignment inaccuracies over time and are difficult to clean, leading to high maintenance costs. BLT’s redesigned and 3D-printed powder dropper base features an optimized, integrated, and lightweight structure, reducing weight by 60% while enhancing long-term operational stability and lowering both maintenance expenses and production lead time.

The blade motion assembly plays a vital role in determining dimensional accuracy. The blade connector—linking the blade holder to the sliding block—ensures smooth motion. BLT’s lightweight redesign reduces the part’s mass by 20%, minimizing inertia during movement and improving powder spreading precision and efficiency.

△ Detailed Overview of BLT’s Intelligent Powder Spreading System

Moreover, BLT’s improved water connector has greatly enhanced the uniformity and stability of the cooling system. Similarly, the 3D-printed camera mount significantly bolsters monitoring system stability.

Metal 3D printing also offers new possibilities for aesthetic customization of machine parts, allowing personalized designs without compromising performance. One such example is the hinge displayed at the exhibition. While retaining its original function of supporting the forming chamber door, the hinge has been reimagined with enhanced visual appeal through additive manufacturing.

△ Traditional Hinge (Top) vs. Improved BLT Hinge (Bottom)

02 Empowering Industries Through the Metal 3D Printing Ecosystem

In industrial manufacturing, cost-efficiency, product yield, and production speed are enduring priorities. Metal 3D printing not only shows vast potential in robotics, civil aviation, low-altitude flight, and new energy sectors but also offers compelling advantages in machinery and hardware manufacturing—delivering superior performance with manageable costs.

By reengineering common component designs through metal 3D printing, companies can swiftly respond to market shifts, enabling iterative innovation while reducing costs and improving quality. This "restructure-optimize-rebuild" cycle breaks free from traditional supply chain limitations, transitioning from standardized to flexible production. It is more than just a closed technical loop—it marks the inception of an ecosystem transformation.

Since its founding, BLT has adhered to the philosophy of “accessible innovation”—delivering practical and affordable solutions. Through integrated hardware-software systems and continuous process innovation, the company strengthens its industrial capabilities, offering economical and inventive manufacturing solutions across diverse sectors. Moving forward, BLT will continue to collaborate with industrial users, embracing strategic transformation and propelling the advancement of China’s new industrialization—empowering industries far and wide through metal additive manufacturing.