Velo3D and Aurelia Technologies Collaborate on 3D Printing for Gas Turbines

Velo3D and Aurelia Technologies Partner to Transform Small-Scale Gas Turbine Manufacturing with 3D Printing \\[n]In a strategic move, metal additive manufacturing company Velo3D has partnered with Texas-based Aurelia Technologies, a developer of high-efficiency, fuel-flexible small-scale gas turbines. This collaboration aims to expand the use of 3D printing in the production of gas turbine systems, aligning with Aurelia's continuous improvement goals. The partnership is set to enhance design consolidation, accelerate iteration, strengthen supply chain resilience, and reduce long-term costs. For Velo3D, this venture adds a new dimension to their portfolio, which primarily focuses on aerospace and defense, by demonstrating the potential of their technology in advanced energy applications. \\[n]### Simplifying Designs and Reducing Failure Points \\[n]Aurelia Technologies is leveraging 3D printing not to create complex geometries, but to simplify designs. By merging multiple parts into fewer, more integrated components, they aim to reduce the number of fasteners, joints, and tolerance stack-ups. This approach minimizes maintenance risks in the high-temperature, high-stress environments that gas turbine components must withstand. According to Karol Hricisak, PE, Director of Technology at Aurelia Technologies, "Additive manufacturing allows us to streamline designs, reduce failure points, and accelerate development while adhering to proven turbomachinery fundamentals and materials science." \\[n]### A Phased Approach to Additive Manufacturing \\[n]The companies are implementing a phased program using Velo3D's Sapphire XC platform. Initial efforts will focus on component feasibility studies, material and process development, and eventual qualification and low-rate initial production. The goal is to identify which high-performance alloy components can benefit most from 3D printing, improving performance, lead times, and manufacturability. Aurelia chose Velo3D for its expertise in metal additive manufacturing, structured qualification methodology, and ability to support both development and scaled production. \\[n]### Supply Chain and Cost Benefits \\[n]Beyond engineering advantages, 3D printing offers significant supply chain and cost benefits. By producing components in-house or on demand, Aurelia can reduce reliance on long-lead forgings, tooling-heavy processes, and large inventory commitments. This flexibility frees up working capital and makes the company more responsive to design changes and shifts in demand. Additionally, 3D printing compresses iteration cycles, allowing geometry updates or new features to move from design to finished part in weeks rather than months. \\[n]### Implications for ASEAN Factories \\[n]For factories in Thailand, Vietnam, Indonesia, and Malaysia, this partnership highlights the potential of 3D printing in transforming traditional manufacturing processes. By adopting similar technologies, ASEAN manufacturers can achieve greater design freedom, reduce production costs, and enhance supply chain resilience. This is particularly relevant in industries such as automotive, electronics, and general manufacturing, where rapid prototyping and efficient production are critical. \\[n]### Concrete Takeaway for Factory Buyers \\[n]Factory buyers in ASEAN should consider integrating 3D printing into their manufacturing processes to stay competitive. By partnering with experienced 3D printing providers like Velo3D, they can leverage the technology to simplify designs, reduce failure points, and accelerate product development. This strategic approach not only enhances operational efficiency but also positions them to meet the growing demands of the market.