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VELO3D AND MEARS EXPAND CAPABILITIES WITH DEDICATED U.S. CU-NI PRODUCTION

The ordered system will add copper-nickel capability to Mears' existing nickel-superalloy and aluminum production fleet.

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Velo3D (VELO) announced that Mears Machine Corporation has ordered its sixth Sapphire XC system, expanding an existing customer relationship.

The new system will be dedicated to copper-nickel, adding in-house printing capability for an alloy family historically produced through casting. It will join five systems already producing parts in nickel superalloys and aluminum. Mears plans to combine copper-nickel additive manufacturing, machining and final inspection within one facility, using its existing operating experience and machine infrastructure.

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Rhea-AI Sentiment measures something else, the tone of the wording.

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How the balance works

Positive

  • Moderate pointMears ordered its sixth Sapphire XC system from Velo3D, dedicated to copper-nickel production.

Negative

  • None.

Key Figures

Sapphire XC system order: 6th system
Sapphire XC system order
6th system
Mears ordered a system dedicated to copper-nickel production

Key Terms

copper-nickel, laser powder bed fusion
2 terms
copper-nickel technical
"The new system will be dedicated to copper-nickel (CuNi)"
An alloy made by combining copper and nickel in varying proportions to produce a metal with improved strength, corrosion resistance and hardness compared with pure copper. Typical compositions range from about 90% copper/10% nickel to 70% copper/30% nickel, and the added nickel reduces electrical and thermal conductivity while increasing resistance to seawater and chemical corrosion, so the material is commonly used for coins, marine hardware, piping, and heat-exchange components. The term denotes the alloy itself and its general properties; exact performance and value depend on the specific copper-to-nickel ratio and any additional alloying elements.
laser powder bed fusion technical
"Some customers are already treating laser powder bed fusion Cu-Ni components"
Laser powder bed fusion is a type of 3D printing where a thin layer of metal powder is spread across a platform and a focused laser melts selected areas to fuse particles together, repeating layer by layer to build a finished metal part. Investors should care because it enables complex, lightweight designs, faster prototyping, and lower tooling costs compared with traditional manufacturing—factors that can reduce production time, cut supply‑chain steps, and open new market opportunities, but may require different quality controls and certification.

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FREMONT, Calif., Oct. 6, 2026 /PRNewswire/ -- Velo3D, Inc. (Nasdaq: VELO) ("Velo3D"), a metal 3D printing technology company that enables customers to build mission-critical metal parts, today announced that Mears Machine Corporation ("Mears"), an Indianapolis-based precision machining and metal additive manufacturing company, has ordered a sixth Velo3D Sapphire® XC system. The new system will be dedicated to copper-nickel (CuNi), giving Mears in-house capability to print parts in an alloy family that has historically been cast.

Velo3D Logo

"The test of production additive manufacturing is whether a customer can qualify once and then continue adding capacity and materials as demand grows," said Arun Jeldi, Chief Executive Officer of Velo3D. "Mears' purchase of its sixth Sapphire XC system demonstrates that kind of confidence in the platform. With five systems already producing parts in nickel superalloys and aluminum, Mears is now dedicating a new Sapphire XC to copper-nickel, bringing a material critical to shipyards and offshore industries into production right here in the United States."

Copper-nickel resists corrosion in seawater and holds its properties across a wide temperature range, which has made it a mainstay in shipbuilding, seawater cooling, condensers, and heat exchangers. Mears' new system will bring that capability into a commercial contract manufacturer's production fleet.

"Following a period of market, product and technical analysis, our move into copper-nickel additive manufacturing is a strategic decision," said James Lloyd, Chief Executive Officer of Mears Machine Corporation. "We are building a vertically integrated Cu-Ni supply chain solution for the industry, with the ability to take a customer from additive design support through additive manufacturing, machining and final inspection—all within one facility. That changes the customer experience significantly by reducing handoffs, shortening the manufacturing chain and giving customers a single accountable partner from concept through finished hardware. For the markets we are targeting, our existing medium-to-large format machining capability is also very well matched to the size and geometry of the components' our customers need."

"Some customers are already treating laser powder bed fusion Cu-Ni components as interchangeable with traditionally cast hardware for selected applications. That creates an important opportunity to provide tooling-free replacements for legacy components, particularly where castings are difficult to source, tooling is no longer available, or volumes do not justify traditional foundry investment. At the same time, additive manufacturing gives engineers far greater freedom to develop next-generation heat-transfer and fluid-management hardware, including more integrated geometries, optimized internal flow paths and designs that would be difficult or impossible to manufacture conventionally"

The Cu-Ni system will join Mears' existing Sapphire XC production fleet, which is already supporting customer programs in Inconel 718, Haynes 282 and CP1 aluminum. Using a common production platform allows Mears to build on existing operating experience, workforce capability, quality systems and machine infrastructure as it introduces the new material. All systems run on Velo3D's Flow™ print preparation software and Assure™ quality reporting. Standardized process controls and software-driven calibration are designed to keep output consistent from machine to machine, so a contract manufacturer serving regulated industries can add capacity behind customer programs it has already qualified, rather than starting over with each new system.

About copper-nickel (CuNi30) additive manufacturing:

  • CuNi30 is a 70-30 copper-nickel alloy widely used in marine and naval systems for its corrosion resistance in seawater.

  • It maintains consistent mechanical and thermal properties from cryogenic temperatures to approximately 400°C.

About Velo3D

Velo3D is a metal 3D printing technology company that enables customers to build mission-critical metal parts. The fully integrated solution includes the Flow™ print preparation software, the Sapphire® family of printers, and the Assure™ quality control system—all powered by Velo3D's Intelligent Fusion® manufacturing process. Learn more at velo3d.com.

Velo, Velo3D, Sapphire and Intelligent Fusion are registered trademarks of Velo3D, Inc. Flow and Assure are trademarks of Velo3D, Inc. 

Forward-Looking Statements

This press release includes "forward-looking statements" within the meaning of the "safe harbor" provisions of the Private Securities Litigation Reform Act of 1995. Words such as "expect", "anticipate", "intend", "plan", "believe", "will", "could", "should", and similar expressions are intended to identify such statements. These include, without limitation, statements regarding the delivery, installation, commissioning and production use of the additional Sapphire XC system at Mears; expected material properties, part density and performance of additively manufactured copper-nickel; and anticipated customer demand for additively manufactured components. These statements involve significant risks and uncertainties that could cause actual results to differ materially, including risks related to the timing of system delivery, installation and customer acceptance; the Company's ability to achieve expected material properties at production scale; changes in customer demand; and the other risks described under "Risk Factors" in the Company's Annual Report on Form 10-K for the year ended December 31, 2025 and its subsequent filings with the SEC. You should not place undue reliance on any forward-looking statements, which speak only as of the date made. The Company undertakes no obligation to update any forward-looking statements except as required by law.

Investor Relations:

Hayden IR

James Carbonara, Managing Director

james@haydenir.com

Media Contact:

Velo3D

press@velo3d.com

Cision View original content to download multimedia:https://www.prnewswire.com/news-releases/velo3d-and-mears-expand-capabilities-with-dedicated-us-cu-ni-production-302899739.html

SOURCE Velo3D, Inc.

FAQ

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What system did Mears order from Velo3D, and what will it produce?

Mears ordered its sixth Velo3D Sapphire XC system, which will be dedicated to copper-nickel. The system will add in-house printing capability alongside Mears' existing nickel-superalloy and aluminum production.

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