Intergalactic Uses Velo3D to 3D Print Aircraft Heat Exchanger Headers in Just Weeks

A new aviation project demonstrates how metal 3D printing can dramatically shorten the time it takes to go from design to working aircraft component. Velo3D announced that aerospace supplier Intergalactic used its metal 3D printing technology to produce critical parts for an aircraft heat exchanger system in just a few weeks.

The components are microtube heat exchanger headers made from Inconel 718, a nickel alloy commonly used in aerospace applications. They help regulate cabin air temperature in commercial aircraft.

From Design to Hardware in Weeks

The parts were printed using Velo3D's Sapphire XC system through the company's Rapid Production Solutions (RPS) program. According to Velo3D, the process allowed engineers to move from design to printed hardware in only a couple of weeks, helping Intergalactic meet strict testing deadlines for the aviation program.

Customers with aggressive program timelines rely on Rapid Production Solutions to get hardware fast without redesign and without lengthy development cycles, said Michelle Sidwell, Chief Revenue Officer at Velo3D.

Complex Geometries Without Redesign

The components feature wide curves and shallow angles that can be difficult to produce with conventional metal powder bed fusion machines. Many systems require support structures or design changes to print these shapes. However, Velo3D's non-contact recoater allows complex geometries to be printed with fewer supports.

This meant the heat exchanger headers could be printed exactly as designed, without needing to redesign the part for manufacturing.

Distributed Manufacturing Potential

The project also highlights how additive manufacturing enables production of the same part in different locations. Because the parts were printed using standard settings on the Sapphire XC platform, the same design could be produced on other Sapphire machines without recreating the process.

Building these heat exchanger headers on the Sapphire XC supported Intergalactic's goal to meet its system-level test schedule and established the groundwork for a scalable path to a distributed supply chain for future production, said Rhett Burton, Intergalactic's supply chain leader.

Heat exchangers are ideal candidates for metal 3D printing because they contain small internal channels and complex shapes that are difficult to machine or assemble using traditional methods.