Divergent unveils large-format metal 3D printer with twelve 2kW lasers

Divergent Technologies has revealed its Monolith One metal powder bed fusion system, a machine boasting twelve 2kW lasers and a significant build volume measuring 700 x 700 x 835 mm. This development is the culmination of 28 months of internal design and engineering, with the Monolith One serving as a core component of Divergent's Adaptive Production System (DAPS).

The substantial machine, standing over eight meters tall and six meters wide, is engineered for continuous, high-throughput operations. It is slated to support the annual production of tens of thousands of munition airframes or hundreds of thousands of critical parts at a new 430,000 sq.ft. facility in Long Beach, California. Currently, six Monolith One units are operational at the company's Torrance, California headquarters, with an additional 64 units planned for the Long Beach facility over the next two years. This expansion is projected to yield an eightfold increase in annual production output for both defense and commercial sector clients.

According to Divergent, the Monolith One utilizes advanced beam shaping laser technology for enhanced process stability and part quality, with its twelve 2kW lasers contributing to a robust deposition rate. The company suggests this system offers significantly increased throughput compared to existing market printers. Its 4-axis scanners with spot-size zoom capabilities facilitate precise energy placement and control. The printer is capable of processing aluminum, nickel, steel, and titanium alloys and incorporates an integrated powder recovery and recirculation system to maintain material quality.

Further enhancing its production capabilities, the Monolith One features a powerful gas flow system (up to 1700m3/hr) for high-energy processing and extended runtimes, along with active thermal control (up to 200°C) to improve reliability and dimensional stability. Exchangeable build modules and software automation are designed for rapid changeovers and reduced downtime, while a permanent filter system with advanced condensate management aims to minimize maintenance and boost operational efficiency and safety.

The Long Beach facility, upon full operation, will house 70 Monolith One systems, alongside other metal 3D printers. This expanded capacity is expected to enable the production of hundreds of thousands of components annually, including missile airframes, warhead casings, automotive subframes, and suspension systems. Divergent anticipates this facility will bolster the region's aerospace and defense manufacturing heritage and create approximately 1,000 direct jobs and thousands of indirect jobs.