Additive Manufacturing

BLT 2024: Pushing The Boundaries Of Metal Additive Manufacturing With Cutting-Edge Technology And Innovation

BLT 2024: Pushing the Boundaries of Metal Additive Manufacturing with Cutting-Edge Technology and Innovation

In 2024, Bright Laser Technologies (BLT) has further cemented its reputation as a prominent player in metal additive manufacturing, driving innovation and setting high standards in technology, quality, and performance. This milestone year has seen major enhancements to its equipment portfolio, remarkable breakthroughs in precision and efficiency, and significant contributions across industries such as aerospace, automotive, mold, robotics, consumer electronics, and academic research. These achievements underscore BLT’s strong capabilities in serial production, reinforcing its position as a trusted industry innovator.

Next-Generation Printing Systems: Enhanced Efficiency and Scalability

BLT has introduced major upgrades to its PBF-LB/M systems, emphasizing efficiency, reliability, and eco-consciousness. The BLT-S600 series, refined over eight years of development, now boasts a build dimension of 650mm × 650mm × 850mm, making it ideal for producing mid-sized parts and large, complex components. Innovations like the integrated build cylinder, intelligent quality detection systems, and a gas- and powder-saving circulation system ensure reliable, sustainable, and safe production.

Similarly, the BLT-S450 underwent a transformative upgrade, showcasing remarkable performance in aerospace, mold, and automotive industries. With a build dimension of 450mm × 450mm × 500mm and multi-laser configurations ranging from 4 to 8 lasers, the system enhances productivity while maintaining precision. The addition of long-life filters and automated powder circulation further cements its reputation as a cost-effective solution for industrial-scale manufacturing.

 

 

Pioneering Precision and Efficiency in Metal Additive Manufacturing

BLT has made groundbreaking progress in ultra-high-precision metal printing and thick-layer printing solutions, addressing the industry’s growing demand for intricate components and faster production cycles. The advanced PBF-LB/M technology achieves surface roughness of Ra 2-3μm and dimensional accuracy within 0.05mm, catering to applications requiring exceptional detail.

Meanwhile, BLT’s thick-layer printing technology—capable of layer thicknesses up to 150μm—delivers unparalleled efficiency, enabling high-quality serial production at significantly reduced costs.


Additionally, BLT has further refined its variable layer thickness printing technology, offering flexible layer thicknesses of 30μm, 80μm, 120μm, and 150μm depending on the specific characteristics of each part, delivering excellent forming quality and exceptional performance.

Advancing Innovation in Aerospace, Automotive, Robotics, and More

BLT’s expertise extends to diverse industries, including aerospace, medical devices, automotive components, robotics manufacturing, and heat exchanger solutions.

BLT has been a trusted partner in aerospace innovation, producing critical components for commercial rockets and satellites. Highlights include contributions to Orienspace’s “Gravity-1” commercial carrier rocket and Land Space’s ZQ-3 vertical takeoff and landing test. Additionally, BLT played an important role in the successful launch of the SmartSat-2A satellite, manufacturing large-scale parts using BLT-S1000 systems. These achievements underscore BLT’s expertise in delivering high-performance materials and optimized manufacturing processes for aerospace applications.

BLT has optimized various automotive components, including rear subframes, steering knuckles, and battery housings, reducing production time while ensuring consistent, high-quality parts that enhance production efficiency. For heat exchangers, BLT introduced three new aluminum alloy models with optimized designs, achieving a 30% increase in efficiency and meeting growing demands for energy-efficient solutions.


In the robotics sector, BLT has harnessed the transformative power of additive manufacturing to redefine the design and production of robotic components. By employing topology optimization and multi-scale configurations, BLT’s PBF-LB/M technology integrates multiple parts into single units, enhancing functionality, reducing weight, and simplifying assembly. Key applications in humanoid robots demonstrate the potential for mass production and the acceleration of next-generation robotics technologies.

BLT’s commitment to innovation is also reflected in its partnerships with universities and research institutions. The company’s systems and materials have facilitated internationally recognized breakthroughs, including studies on biomaterials for bone tissue repair, high-strength steel for cryogenic applications, and degradable porous scaffolds for large-scale bone defect treatments. Notably, a publication in Nature highlighted the exceptional fatigue resistance of titanium alloys produced using BLT equipment, supporting research on near-void-free 3D printing technology and expanding their potential in aerospace and other critical industries.

Advancing Industry Standards in Quality and Digital Manufacturing

Quality assurance remains at the heart of BLT’s innovations. The company’s enhanced quality monitoring systems integrate intelligent tools for pre-build and in-process stages, ensuring traceability and reliability. Features such as powder bed detection, defect detection platforms, and precise laser alignment have redefined industry standards.

Complementing these advancements is the upgraded BLT-MES system, a digital manufacturing solution that bridges planning and execution. With real-time data collection, production monitoring, and intelligent resource management, the system optimizes production cycles, supporting the era of mass production in metal additive manufacturing.

Expanding Global Reach and Showcasing Excellence at Industry Events

In 2024, BLT strengthened its global presence by partnering with key players across Asia, Europe, Africa, and beyond. BLT has forged deep partnerships with Lincsolution in Korea and Orix in Japan, working closely to deliver high-quality metal additive manufacturing solutions and drive technology adoption, including the launch of the ‘Tokyo 3D Lab’ showcasing multi-industry parts produced with BLT’s PBF-LB/M systems, while strategic partnerships in Europe and Africa expanded access to our technologies. In aerospace, BLT’s successful work package with Airbus Atlantic on the A320 O-Ring reinforced our expertise in high-performance, mass-production solutions. At major global industry events, from the US to Germany, South Korea, Japan, and beyond, BLT showcased innovations in automated metal 3D printing, advanced software, and real-world applications across sectors like aerospace, automotive, and consumer electronics. These efforts highlight our commitment to pushing the boundaries of metal additive manufacturing and creating value for our partners worldwide.

Shaping the Future of Additive Manufacturing

As we step into 2025, BLT celebrates a year of remarkable achievements that have redefined the possibilities of metal additive manufacturing. From cutting-edge systems and materials to groundbreaking applications across industries, BLT continues to lead innovation, delivering customized solutions that empower partners and shape the future of manufacturing. BLT looks forward to collaborating with industry leaders across various fields to drive progress and create new opportunities together.

Additive Manufactured Parts Improve The Overall Performance Of Semiconductor Manufacturing Machines

Additive manufactured parts improve the overall performance of semiconductor manufacturing machines

The additive manufacturing (AM) technology of TRUMPF makes semiconductor manufacturing systems more precise and efficient. “Semiconductor manufacturers can reduce scrap and cut costs with AM technology. The innovative approach of using additive manufactured parts enhances the functionality and precision of semiconductor manufacturing machines and paves the way for more efficient production processes”, said Marco Andreetta, responsible for the semicon industry at TRUMPF. The chip industry requires machines that work with optimal precision and repeatability with performance specifications in the nanometer range. The smallest of deviations can lead to defective chips, i.e. expensive scrap. At Formnext, the leading trade show for additive manufacturing, held in Frankfurt, the high-tech company TRUMPF showcased additive manufactured sample parts for the semicon industry, such as manifolds used in water and gas lines of semiconductor manufacturing equipment.

Semicon industry reaps benefits from AM technology

The complex machines in the semiconductor industry depend on the precision of each individual component. Fluid and gas manifolds are examples of this fact. Because of their design, the traditional manufacture of complex fluid manifolds resulted in large, heavy parts that have abrupt fluid flow and stagnant zones and could be prone to leakage. The resulting pressure drops and flow-induced vibration have a negative influence on the semiconductor capital equipment. “With AM technology, suppliers of semicon capital equipment can avoid the traditional complex manufacturing assembly and consolidate several parts into one, improving yield and reliability”, said Andreetta. The optimization of the manifolds leads to more efficient and robust components, ultimately improving the overall performance of semiconductor manufacturing machines. AM technology of TRUMPF enables the production of components for semicon machines with enhanced stiffness and reduced weight, crucial for the high-performance demands of semiconductor manufacturing. AM-manufactured fluid manifolds have fewer pressure drops, mechanical disturbances and lower flow-induced vibration. The geometrical freedom of AM can help reduce possible leakage points and increase part performance and reliability.

Semicon industry can rely on TRUMPF AM technology

The quality required for parts used in semiconductor manufacturing machines is unparalleled, and a challenge for any manufacturing technology. With its monitoring solution for 3D printing, TRUMPF makes it possible to fulfill these requirements with automatic multi-laser alignment (AMA) and melt pool monitoring. AMA offers TruPrint users fully automated online monitoring and correction of the positioning of the laser beam paths in relation to each other – accurate down to a few micrometers. TRUMPF premiered the second release of the AMA system at Formnext 2024, which enables faster acquisition and finer correction. The patented system visually acquires the position of master and slave and corrects the second one. The procedure is performed between the production of individual layers, with an interval set by the user. TRUMPF technology also monitors the melt pool live during the printing process. “This not only ensures quality, but also potentially reduces costs,” said Andreetta. That is possible because live monitoring of the melt pool during the manufacturing process could reduce expensive non-destructive tests (NDT) such as a computer tomography (CT) scan of the component after production.

Additive manufactured manifold

The AM technology of TRUMPF enables the production of components for semicon machines with enhanced stiffness and reduced weight. (Image: TRUMPF)

Hexagon Acquires Inspection And 3D Modelling Software Capabilities From 3D System

Hexagon acquires inspection and 3D modelling software capabilities from 3D System

Hexagon today announced the acquisition of 3D Systems’ Geomagic suite of interoperable software packages, which are used to create high quality 3D models from multiple sources, including laser scanning.

The Geomagic suite, which includes products such as Design X, Control X, Freeform and Wrap, is capable of automating the processing of 3D scan data to build digital models from physical objects, which can then be used to generate history based parametric CAD models for use in product manufacturing. The Geomagic software tools can also be used to undertake initial free-form design, modify existing CAD models and to accurately measure and inspect parts for quality control purposes when finished. The acquired capabilities will strengthen the existing software portfolio of Hexagon Manufacturing Intelligence and combine with its leadership in portable metrology sensors to deliver a sophisticated suite of solutions across the full range of manufacturing applications.

“The combination of Geomagic and our existing solutions will further strengthen our market leadership in 3D metrology and reengineering, demonstrating our commitment to deliver increasingly user friendly tools capable of executing complex tasks, so our customers can bring innovative, high quality products to the market at speed and with confidence. We look forward to welcoming the Geomagic team to Hexagon.” said Norbert Hanke, interim President and CEO.

Hexagon will pay a purchase price of $123M for the Geomagic software business, on a cash and debt free basis. In 2023, the acquired software business had around 100 employees, generated revenues of around $30M and delivered operating margins accretive to those of the Manufacturing Intelligence division. Completion of the transaction is subject to regulatory approvals and other customary conditions, which are expected to be fully completed by early in the second quarter of 2025.

inspection and 3D modelling software capabilities

For further information, please contact: Tom Hull, Head of Investor Relations, Hexagon AB, +44 7442 678 437, [email protected]

Anton Heikenström, Investor Relations Manager, Hexagon AB, +46 8 601 26 26, [email protected]

 Hexagon is the global leader in precision technologies at any scale. Our digital twins, robotics and AI solutions are transforming the industries that shape our reality.

Hexagon (Nasdaq Stockholm: HEXA B) has approximately 24,500 employees in 50 countries and net sales of approximately 5.4bn EUR. Learn more at hexagon.com and follow us @HexagonAB. 

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