BLT at Formnext 2024: Demonstrating Excellence in Metal Additive Manufacturing for Serial Production

From November 19 to 22, Bright Laser Technologies (BLT) attended Formnext in Germany for the ninth time, showcasing its advanced solutions for serial production in metal additive manufacturing. The exhibit, themed “Your Road to Serial Production,” featured innovations across aerospace, consumer goods, automotive, and tooling, earning widespread recognition from international customers.

01 | Introducing the Upgraded BLT-S450: Advancing Efficiency and Intelligence in Serial Production
At Formnext, BLT unveiled the upgraded BLT-S450, designed to meet the demands of efficient, intelligent serial production. With a build dimension of 450mm×450mm×500mm (excluding a 50mm base plate) and configurable with 4, 6, or 8 lasers, the BLT-S450 is optimized for serial manufacturing. Its predecessor, with over 60 units installed and operating reliably for more than three years, has already proven its exceptional stability. The latest iteration offers enhanced efficiency, reliability, intelligence, and cost-effectiveness, catering to industries such as aerospace, automotive, tooling, and consumer electronics.

The system features a modular powder circulation solution, including the Powder Sieving Machine BLT-SF400, Automatic Powder Recycling Module BLT-HS03, Powder Supplying Machine BLT-GF500, and Powder Collection Machine BLT-WL200. This setup automates powder recycling, sieving, and supplying, eliminating the need for manual intervention and significantly enhancing production efficiency.

A live demonstration at the booth showcased the serial production of nozzles with intricate internal channels designed to atomize and mix fuel with oxidizers for stable and efficient combustion. Additive manufacturing provides the design flexibility needed for such complex structures, enabling higher combustion efficiency. The BLT-S450 can produce up to 67 nozzles in a single run, achieving exceptional productivity and consistency. This upgraded BLT-S450 showcased during the exhibition has been sold and will be deployed at our client’s DNV-certified AM hub to support operations in KSA and UAE.

The upgraded BLT-S450 (Build Dimension: 450mm×450mm×500mm)

02 | Driving Innovation: Breakthroughs in Established Fields and Pioneering New Frontiers
In the commercial aerospace sector, BLT showcased its cutting-edge advancements with the presentation of the array panel at its booth. This array panel serves as the carrier for radiating elements in array antennas. Fabricated from aluminum alloy, the panel features a lattice structure with a minimum wall thickness and strut diameter of just 0.5mm, meeting an overall dimensional tolerance of ±0.5mm for a size of 1125 mm×20mm×1300mm. The lattice design not only ensures the required rigidity but also significantly reduces weight, exemplifying the benefits of additive manufacturing in creating lightweight, integrated structures. On February 3, 2024, the SmartSat-2A Satellite successfully launched, with BLT providing one satellite body structure and three array panels. The array panel’s performance has already been validated in practical applications, demonstrating its effectiveness in lightweight, integrated designs for space applications.

BLT 3D-printed Array Panel

In the consumer products sector, BLT has already achieved stable serial production. Featured products include a phone frame, foldable phone hinge mechanism, full substrate hinge cover, and steam nozzle. The full substrate hinge cover, manufactured using the PBF-LB/M process, achieves a density of 99.98%, significantly surpassing the 95%-99% range of MIM and BJ processes. This exceptional density results in superior polishing performance, making it ideal for hinge covers and other visible components. In terms of dimensional accuracy, the PBF-LB/M process controls tolerances within ±0.2%, a significant improvement over the 15%-20% shrinkage and sintering deformation seen with MIM. Additionally, PBF-LB/M demonstrates lower energy consumption compared to BJ and MIM processes, aligning with sustainable manufacturing goals and offering a more environmentally friendly solution for future production needs.

In the automotive sector, BLT unveiled a 3D-printed rear subframe (1230mm x 845mm x 253mm) featuring a lightweight, optimized topology achieved through Bidirectional Evolutionary Structural Optimization (BESO). Weighing 21kg, it is 20% lighter than the original die-cast aluminum design, with a 2mm-thick hollow lattice structure that avoids discontinuities caused by traditional processes. BLT also showcased steering knuckles and battery brackets tailored for Western markets, offering reduced weight, shorter production cycles, and lower costs.

BLT 3D-printed Rear Subframe

BLT also debuted innovative smart manufacturing applications in emerging fields, including robotic components like finger joints, motor bases, and hydraulic thighs, as well as tooling solutions such as milling cutter heads and tool holders. Highlights of the exhibit also included ultra-small curved heat exchangers, large-layer thickness printing techniques, and high-precision manufacturing technologies, which drew significant attention from visitors.

BLT 3D-printed Heat Exchanger

03 | BLT Showcases Proprietary High-Performance Powders and Expands Industrial Production Base
Leveraging the unique advantages of metal additive manufacturing, BLT has developed a range of high-performance materials, including superalloys and titanium alloys. At this year's Formnext exhibition, BLT presented nine powder materials, including titanium alloy and superalloy. These advanced materials, spanning applications in aerospace, energy, and medical sectors, demonstrate BLT’s strong expertise in raw material R&D.

To meet the rapidly growing market demand for additive manufacturing, BLT is expanding its production capabilities by building a high-quality titanium alloy and superalloy powder production line. The new facility, with a total construction area of approximately 69,800 square meters, will include production workshops, inspection and testing centers, and supporting facilities. Once completed, the project is expected to increase annual production capacity significantly, significantly enhancing the industrialization capabilities of the entire metal additive manufacturing value chain.

BLT Powder Display Wall

04 | Software Ecosystem: Empowering the Full Additive Manufacturing Workflow
At this year’s exhibition, BLT showcased its independently developed software ecosystem—BLT-BP and BLT-MES—highlighting the company’s deep expertise and innovation in metal additive manufacturing software. From the production of its first machine, BLT established a dedicated software development team focused on creating digital solutions tailored to every stage of the additive manufacturing process.

BLT Software Display Wall

BLT-BP, the Smart Build Planning Software, draws on over 10 years of experience with hundreds of PBF-LB/M machines and systems. It is designed to deliver key benefits, including a multi-scanning strategy for enhanced precision, robust client parameter confidentiality, efficient slicing for faster processing, and a user-friendly interface for seamless operation.

BLT-MES, leveraging data from over 400 machines, offers real-time monitoring, intelligent management, and flexible customization for efficient production management. Together, this system streamlines workflows, enhance manufacturing transparency, and empower customers to meet the demands of Industry 4.0.

BLT Team at Formnext 2024

At this year’s exhibition, BLT presented its customized automated and intelligent solutions designed for overseas clients, focusing on enabling serial production. By enhancing localized services, BLT helps global customers unlock the potential of additive manufacturing, making serial production more efficient and practical.