Mears Machine Corporation will use the 3D printer to produce parts in Haynes 282 alloy, the company said.
INDIANAPOLIS—Precision machining company Mears Machine Corporation recently purchased its fourth Sapphire XC printer to bolster its additive manufacturing capabilities in response to customer demand. The Velo3D Sapphire XC printer will be configured to produce parts in Haynes 282 alloy, according to a release from Mears Machine.
The new order is expected to be delivered in the second quarter of 2025. It is said to underscore Mears Machine’s commitment to adopting advanced manufacturing technologies, and it follows the previous purchase of three Velo3D Sapphire XCs in 2024, the release stated.
According to Mears Machine, the Velo3D Sapphire XC printer sets itself apart in the laser powder bed fusion industry with its unique print capabilities and large format. The printer uses eight 1-kilowatt lasers and can produce parts 600mm in diameter and 550mm in height.
Haynes 282 is a strengthened superalloy developed for high-temperature applications, primarily for aerospace propulsion systems, industrial power generation, nuclear power, and critical CO2 systems. It possesses a unique combination of strength, thermal stability, and fabricability not found in currently available commercial alloys. Printed parts also have better weldability, creep resistance in the range 1200-1700F (649-927C), oxidation properties, and great thermal stability, the company said in the release.
“Integrating the Velo3D Sapphire XC printer into our operations has represented a significant leap forward in addressing the evolving needs of our existing customers,” said Mears Machine Executive Chairman Roger Mears, in a statement. “The new industries and customer base attracted by this capability has exceeded our expectations. This technology empowers us to efficiently deliver complex, high-quality components to our customers. Coupled with our world-class machining capability and post-process supply chain management experience, we are positioned as a leading partner in the additive manufacturing landscape.”
Mears Machine manufactures components for gas turbines, defense, missile defense, rocket launch, orbital vehicles, and advanced propulsion systems. Its manufacturing capabilities are reported to enable production of components from 1mm/0.040 inch to 2m/80 inches in diameter. They include critical rotating components, casings and structures, precision components, large additive hardware, and complex fabrications, the company said.
“Our customers’ demands have increased, and we have met production with Velo3D’s highly scalable additive manufacturing solution, which makes us unique in the industry,” Roger Mears added. Mears Machine has extensive experience machining and welding nickel superalloys, enabling the company to provide a full service to its customers.
A nickel-based superalloy, Haynes 282 is reported to have greater strength at higher temperatures, as well as improved corrosion and creep resistance, versus Inconel 718. Applications for gas turbines include combustion liners, vane rings, and nozzle components.
“Haynes 282 is challenging to machine, and additive manufacturing can reduce the amount to be machined,” the release stated.
Mears Machine Corporation, founded in 1966, is based west of Indianapolis, in Avon, Indiana. The company said it has more than 100 machining centers and 100 employees.