Velo3D’s Rapid Production Solutions Paves Path for Faster Aviation Component Production, Enabling Distributed Supply Chains
Accelerated Component Production with Velo3D RPS Gives Intergalactic a Competitive Edge
Velo3D is making waves in aviation manufacturing—but not through price action. Instead, the spotlight is on how its Rapid Production Solutions (RPS) helped Intergalactic quickly take IN718 microtube heat exchanger headers from initial design to printed parts in just a few weeks. These components, crucial to a new mass-produced commercial aircraft’s cabin air heat exchanger assembly, were manufactured on the Sapphire XC system, known for its large-format Inconel 718 printing capabilities.
Technological Innovation: Faster Timelines Without Design Compromises
One of the pressing challenges in aerospace has always been the tension between rapid development and uncompromised design. Velo3D’s RPS and Sapphire XC platform address this with non-contact recoater technology and advanced production parameter sets. Traditionally, legacy laser-powder-bed-fusion systems forced concessions in design due to hardware limitations. With Sapphire XC, parts featuring complex geometries—including sweeping low angles and large-radius transitions—were printed as originally intended, requiring minimal internal supports and erasing the slowdowns of part-specific development cycles.
| Key Benefits | Velo3D RPS Impact |
|---|---|
| Rapid Prototyping | From design to hardware in a matter of weeks, ideal for programs with aggressive test schedules |
| Design Freedom | Manufactures complex geometries without need for extensive internal supports |
| Standardization | Utilizes production-ready IN718 settings, eliminating case-by-case parameter development |
| Supply Chain Flexibility | Enables distributed manufacturing—identical parts can be produced worldwide across validated systems |
Distributed Supply Chain: Scalable, Predictable Production
Perhaps the most forward-looking aspect of this project is the creation of a digital technical data package (TDP) using Velo3D’s standardized approaches. This means that, once validated, these parts can be produced on any Sapphire or Sapphire XC printer worldwide—supporting a distributed, scalable supply chain. As Intergalactic’s supply chain leader, Rhett Burton, put it, the project not only enabled Intergalactic to hit system-level test deadlines but also "established the groundwork for a scalable path to a distributed supply chain for future production."
Broader Implications for Aviation Manufacturing Programs
The aviation sector is notoriously cautious about changing processes, especially with mission-critical parts. However, Velo3D’s latest collaboration demonstrates how leveraging advanced additive manufacturing can dramatically shrink development timelines and de-risk future scaling. For manufacturers facing tight deadlines and high reliability requirements, the ability to move rapidly from prototype to scalable production—without requalifying machines at every site—could be a game changer.
Takeaway: Is this the Model for Future Aerospace Supply Chains?
For those following trends in aerospace manufacturing and 3D printing, Velo3D’s RPS partnership with Intergalactic signals a shift toward digital, distributed, and accelerated production environments. The implications extend beyond one program—suggesting a new norm where design freedom and supply chain agility coexist. As more aviation programs look toward digital inventory and on-demand production, it will be worth watching how quickly this model is adopted across the industry.
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