Mears Machine Corporation orders fifth Velo3D Sapphire XC LPBF system, options two more for aerospace and defense capacity

Mears Machine Corporation has ordered a fifth Velo3D Sapphire XC laser powder bed fusion system and secured options on two additional units to expand metal 3D printing capacity for aerospace, defense, energy, and space technology programs. The new machine targets parts in Inconel 718, Haynes 282, and CP1 aluminum, nickel-based and aluminum alloys used in thermally and mechanically stressed components. The Sapphire XC platform is built for larger, geometrically complex metal parts. CEO James Lloyd said the purchase supports lead-time responsiveness for existing customers while adding capacity for larger production programs, and Velo3D CEO Arun Jeldi framed the order as evidence that manufacturers are moving from prototype work toward scaled, certified production.

Mears is standardizing its growing fleet on Velo3D's Flow build-preparation software and Assure quality-documentation system, with automatic calibration meant to keep process parameters consistent across machines and sites. That consistency matters for aerospace and defense qualification, where a certified process typically needs to reproduce across multiple systems or locations rather than stay tied to one machine. The order reflects service bureaus building repeatable production fleets rather than single demonstration cells, aimed at programs that need decentralized or redundant manufacturing capacity.

The two-unit option suggests Mears expects sustained demand rather than a one-time capacity bump.