As a core component connecting the coaster train to the track, the boogie supports the carriage, guides its movement, and absorbs dynamic impacts from the track, ensuring stable and safe operation even under high-speed, complex maneuvers.

Produced from aluminum alloy AlSi10Mg, the topologically optimized boogie frame measures 570mm × 500mm × 400 mm and weighs just 17.2 kg. It replaces traditional multi-part welded assemblies, exemplifying how large-scale metal AM is transforming the amusement rides sector.

Highlights

Integrated Design: The AM-produced frame eliminates welds and mechanical junctions. This integrated approach not only enhances load distribution, stiffness, and material efficiency but also delivers greater structural integrity and superior reliability.

Lightweight Innovation: Weighing only 17.2 kg, the component is 60% lighter than its welded steel counterpart, providing a superior strength-to-weight ratio, enhanced dynamic response, and lower operational inertia. For amusement parks, it translates directly into significant energy savings of 20-30% annually and reduced wear on other operating components like wheels and bearings.

Ride-Tailored Durability: The geometry of the frame is optimized for high fatigue resistance and dynamic loading. This ensures an extended service life, enhanced safety, and a minimized risk of operational failure, instilling confidence in both park operators and thrill-seekers.

Streamlined Production & Reduced Costs: The rapid transition from 3D model to physical part significantly shortens component production time. Moreover, the integral design requires less maintenance and inspection, drastically lowering overall operational costs for amusement parks by minimizing downtime and extending the service life of the roller coaster.

BLT and EME entered into a strategic partnership at the Formnext 2023. The cooperation has been further deepened following the formal delivery of the BLT-S800 in June of this year.

The collaboration between BLT and EME demonstrates the potential of metal AM in producing large, high-performance industrial parts. It also showcases a clear path toward more efficient and cost-effective construction and operation of amusement rides.

The successful realization of this project was supported by Extreme Analyses Engineering, an engineering office that specializes in the design of additively manufactured components using dedicated fatigue-oriented software and methodologies.

The copper inner wall was integrally printed on six-laser BLT-S615 from high-performance CuCrZr powder.With final dimensions of φ502 mm × 946 mm and a weight of 35 kg, this component demonstrates BLT’s strong capability in the precision forming of large-scale, complex-flow-channel structures.

High-Performance CuCrZr Alloy: The Cornerstone of Part Reliability

The component utilizes CuCrZr (Copper Chromium Zirconium), a precipitation-hardened copper alloy with a copper matrix micro-alloyed with elements such as chromium and zirconium. This material retains the excellent thermal conductivity of pure copper while offering significantly enhanced strength and hardness, along with good high-temperature deformation resistance and corrosion resistance. This combination of properties ensures that the thrust chamber’s inner wall can achieve efficient heat dissipation while maintaining structural integrity and stability under extreme service conditions of high temperature and high pressure, thereby guaranteeing the long-term reliable operation of the engine.

Integrally Formed Cooling Channels: Enabling Optimized Heat Dissipation

Traditional manufacturing processes are constrained by machining capabilities, making it difficult to construct complex and intricate conformal cooling channels inside components. These limitations restrict further improvement of the combustion chamber’s heat dissipation efficiency and performance.The complex internal cooling channels within the thrust chamber, monolithically formed by metal 3D printing technology, not only increase the heat exchange area but also ensure uniform coolant flow throughout the passages, thereby preventing localized overheating. This innovative design of complex flow channel structures can significantly enhance the engine’s cooling efficiency and extend its service life, providing an effective solution for heat dissipation challenges in high-thrust liquid rocket engine combustion chambers.

Furthermore, by integrating the cooling channels with the inner wall in a single manufacturing process, the need for traditional welding is eliminated. This not only prevents potential welding defects but also substantially reduces the production timeline.

GSH is a leading company specializing in precision manufacturing, contract manufacturing, and industrial automation solutions, delivering cutting-edge engineering services to industries such as semiconductors, data storage, electronics, electrical, and biopharmaceuticals. With strong technical capabilities and an extensive customer network, GSH continuously responds to the growing local demand for advanced manufacturing technologies.

Both BLT and GSH are committed to delivering reliable, high-quality solutions that help customers enhance performance and improve manufacturing efficiency.Through this partnership,GSH will leverage BLT’s highly efficient and intelligent metal 3D printing equipment together with its profound technological expertise to provide local clients with more convenient one-stop additive manufacturing support. Meanwhile, BLT will tap into GSH’s broad customer base to further expand its overseas market presence and drive the widespread adoption and development of metal additive manufacturing technology in Malaysia.

Designed for PBF-LB/M, this intelligent quality system integrates online monitoring and offline analysis to manage the full printing lifecycle, ensuring process visibility, control and traceability. Using multi-source data fusion and AI-driven analysis, it delivers end-to-end quality management: real-time defect detection and feedback, coupled with post-process risk assessment.

Online Monitoring With Process Visibility and Intelligent Control

The online monitoring module automates defect recognition and correction with advanced vision algorithms, reducing human effort and improving detection accuracy. Key functions include powder spreading online monitoring and scanning online monitoring.

Powder spreading online monitoring enables real-time powder bed quality inspection, detecting defects like powder shortage, uneven powder spreading, collapse and recoater collision, and making automatic corrections to prevent defects early.

Scanning online monitoring supports real-time laser scanning quality inspection, spotting issues like burnt spots and slag buildup, enabling immediate alerts for operator intervention.

Offline Analysis Offers Precision and In-depth Traceability

The offline analysis module supports quality management and process optimization, using post-print data to evaluate part quality, pinpoint risk areas, and improve processes. It brings together 3D model visualization, defect record management, multi-source data fusion dashboard and one-click quality report generation.

3D model visualization, leveraging 3D reverse modeling, reconstructs part models to precisely map AI-identified defects onto a digital twin. This enables users to intuitively grasp risk distributions and overcomes the limitations of traditional defect locating.

Defect record management enables users to rate defect risks, manage defect lists, customize detection model sensitivity and report abnormal issues with one click. User-submitted defect samples continuously refine AI models, enhancing accuracy over time.

The multi-source data fusion dashboard accesses and aligns multidimensional data, including printing parameters, environmental data, machine and system status and visual images of powder spreading and melting. Its one-click anomaly tracing feature helps users trace defect origins, solving issues of fragmented data and delayed assessments.

One-click quality report generation presents risk layers, defect locations and types, and their associated abnormal images, building customer trust with transparent traceability and evidence-based delivery.

Custom Upgrades Offer Even More Value

To meet diverse application needs, BLT-PrintInsight offers three professional value-added packages:

Defect Self-Training Platform

Allows users to customize detection models using their own defect samples.

Near-Infrared Melt Pool Monitoring

Captures real-time thermal radiation signals to generate thermographic maps, enabling precise identification of overheating or lack of fusion.

Video Monitoring

Records the full printing process with support for playback and automatic cleanup.

Get more details on the required hardware configurations for these value-added packages here.  //m.maochangkai.com/en/blt-print-insight/

Enabling Data-Driven Quality Management  

BLT-PrintInsight leverages online monitoring to collect process data in real time, while offline analysis performs deep examination and intelligent diagnosis. Together, they provide the insights needed for process improvement and machine and system control, establishing a robust, data-driven quality framework that helps users produce better parts faster and with greater confidence.

Intelligent Detection. Assured Reliability. Experience BLT-PrintInsight first-hand at the BLT booth at Formnext 2025, Hall 12.0, Booth D81.

 Booth M282

 March 11-14, 2025

 KINTEX, South Korea

Discover how our additive manufacturing technology optimizes production for industries like automotive, aerospace, medical, and mold manufacturing. As metal 3D printing becomes a key driving force for global manufacturing advancements, BLT will continue to work with Lincsolution to drive technological innovation and industry transformation.

Join us on Day 2 as we unveil the future of additive manufacturing—pushing the boundaries of precision, efficiency, and innovation. Whether you’re in automotive, aerospace, mold manufacturing, or beyond, our solutions are designed to transform your production process.

 Let’s connect and explore new possibilities together! See you at #INTERMOLDKOREA2025!

Dive deeper into BLT and explore our AM turnkey solutions at //m.maochangkai.com/en/

For inquiries, please contact us at sales.global@xa-blt.com

Behind this groundbreaking achievement lies a powerful collaboration between BYD and Bright Laser Technologies (BLT), whose metal additive manufacturing (3D printing) technology played a pivotal role in developing the world’s first integrated 3D-printed high-performance car body.

A Global First: The Integrated 3D-Printed High-Performance Body

At the EuroCarBody 2025 conference held from October 14–16, BYD unveiled the Yangwang U9X’s integrated 3D-printed body structure, the first of its kind in the world. The presentation captivated the audience and earned the highest score from the professional jury, underscoring the innovation’s engineering significance.

The development of the U9X body represents a revolutionary step toward the future of intelligent manufacturing, combining BYD’s automotive expertise with BLT’s leadership in metal 3D printing. By leveraging additive manufacturing, the U9X body achieves unprecedented design freedom and structural integration, realizing both track-level stiffness and outstanding crash safety — while also attaining industry-leading lightweight performance.

Lightweight Strength: Redefining Structural Optimization

The U9X’s body exemplifies lightweight construction and structural integration, two key advantages made possible by BLT’s engineering innovations.

Using topology optimization, BYD team implemented an internal structure of hollow chambers and reinforcing ribs. This approach enhances torsional stiffness by more than 200% compared with a solid structure of the same mass, ensuring optimized strength distribution and superior crash performance.The high-strength aluminum alloy structure, produced using BLT’s advanced 3D printing technology, reduces body weight by over 30% compared with conventional manufacturing solutions.

With its decade-long experience in automotive component engineering, BLT provided a one-stop solution encompassing structural optimization, part printing, post-processing, and inspection — guaranteeing performance consistency across every stage of production.

Complete vehicle body structure

Component structure of the vehicle bod

High Precision Manufacturing: Large-Format Printing at Scale

Key body components of the U9X were printed using BLT’s large-format metal additive manufacturing systems, including the BLT-S1000, BLT-S615, and BLT-S815.

Thanks to BLT’s proprietary large-format dimensional control technology, over 90% of the printed surfaces maintained dimensional deviation within ±0.5 mm, ensuring precision and repeatability at an industrial scale.

BLT currently operates more than 200 large-format systems (with build volumes exceeding 450×450×500 mm) — one of the largest fleets of its kind worldwide. This robust manufacturing capacity, combined with mature multi-machine coordination and a stable process control system, enables cross-equipment and cross-batch consistency. It provides the dual assurance of scalability and quality for the mass production of high-end automotive components.

Beyond the Body: 3D-Printed Calipers for Durability and Reliability

In addition to the body structure, BLT also delivered 20 sets of high-performance 3D-printed brake calipers for the U9X, all of which successfully completed the Nürburgring endurance tests.

Through topology optimization, the calipers achieved 20–30% weight reduction while incorporating internal oil channels and inserts directly into the printed structure. This not only eliminates assembly steps but also significantly enhances durability and reliability under extreme track conditions.

Dimensional control was maintained to exceptional standards — ±0.5 mm for front calipers and ±0.3 mm for rear calipers. Each part achieved a density greater than 99.5% and passed radiographic inspection with no internal defects, demonstrating BLT’s mastery of precision additive manufacturing for high-performance applications.

A Benchmark for Metal 3D Printing in the Automotive Industry

The collaboration between BYD and BLT marks a milestone in the application of metal additive manufacturing within the automotive industry. From structural innovation to real-world record-breaking performance, the Yangwang U9X embodies the synergy between advanced design and cutting-edge manufacturing. This success reinforces the immense potential of metal 3D printing to revolutionize automotive engineering — enabling lighter, stronger, and more efficient vehicles for the next generation of mobility.

As BLT continues to push the boundaries of metal additive manufacturing, it remains committed to empowering global automakers with turnkey solutions, unlocking new possibilities for high-performance, intelligent, and sustainable automotive manufacturing.

The event was attended by BLT’s Chairman and Chief Executive Officer Xue Lei, Deputy General Manager Jia Xin, Deputy General Manager Yang Donghui, General Manager of the European subsidiary Gary Ding, Head of Oversea Business Dept. Eliza Duan, and other management representatives.

BLT Chairman and Chief Executive Officer Xue Lei welcomed global partners in his conference address, highlighting BLT’s commitment to technological innovation and enhanced services. He also called for collaboration to advance additive manufacturing into an era of industrial-scale application, urging distributors to act as long-term strategic partners who deliver full-process solutions and support for customer success.

Jia Xin, Deputy General Manager, affirmed BLT’s commitment to providing continuous, all-around support across product solutions, market strategies, and after-sales services. He underscored that company’s partnership with agents to is aimed at fully implementing the path from innovation to industrialization to empower industrial clients.

During the event, distributors experienced BLT’s latest equipment lineup, closed-loop software ecosystem, and extensive metal powder portfolio through live demonstrations and industry-focused application sessions. Additionally, distributors from North America (GoEngineer) and EMEA (CadXpert) shared insights and practical experiences from their respective regional markets, providing valuable reference points for implementing projects effectively.

The global distributor delegation visited BLT’s headquarters campus. They observed the BLT’s equipment, printing services, and smart factories raw materials, and toured some of the ongoing projects that are open to external visitors.

The conference concluded with an awards ceremony recognizing outstanding distributors for their achievements in growth, collaboration, and market expansion, celebrating their contributions to advancing metal additive manufacturing globally.

The Global Distributor Conference comprehensively demonstrated BLT’s technological strength and industrial capabilities in the field of metal additive manufacturing. This event helped strengthen the global distributor network, laying a solid foundation for providing efficient and professional full-lifecycle additive manufacturing solutions to customers worldwide.

Against the backdrop of continuously evolving industrial production demands, traditional single-machine setups are increasingly inadequate in meeting the stringent requirements for efficiency and cost-effectiveness in metal additive manufacturing. In response to market trends and industry challenges, BLT has deeply integrated automation technology and intelligent control systems to connect previously fragmented production processes, resulting in a smart production system with strong production capacity and continuous operation capabilities.

The BLT automated production line unit integrates eight printing devices and includes a master control module, powder circulation module, material handling module, powder cleaning module, substrate disassembly module, and waste recycling module. It covers key stages of metal 3D printing and offers the industry a brand-new mass production solution.

Innovative Printing System for More Efficient and Higher-Quality Manufacturing

The production line is equipped with printing systems utilizing PBF-LB/M technology, integrating innovative functions such as automatic build plate leveling, automatic powder recoating and inspection, automated printing, and automatic build chamber cleaning to ensure efficient and stable operation. By employing distance measurement technology, the printing systems automatically locate the printing plane, significantly reducing positioning time. This approach also minimizes uncertainties associated with manual intervention, enabling more precise platform positioning and higher consistency in mass production quality.

The equipment features various one-click functions to reduce preparation time. During the printing process, it supports intelligent operations such as bidirectional dynamic powder recoating, automatic recoating monitoring and correction, as well as real-time process monitoring and closed-loop control. These capabilities continuously push the limits of printing efficiency and quality.

Closed-Loop Powder Management for a Sustainable Production Environment

The powder circulation module of BLT’s automated production line consists of a central powder station, powder transport modules, and transfer pipelines, establishing an efficient “one-to-many” powder circulation system. With a powder transfer rate of up to 4L/min, it meets the high-efficiency production demands of mass-scale equipment.

During the printing process, the system automatically handles powder supply, recovery, and sieving. Upon completion, it reclaims and sieves the powder from the powder dumping and cleaning modules. The sieved powder is then reused by the printing equipment, forming a closed-loop powder management system.

In terms of powder management, the BLT automated production line adopts a fully enclosed design, with all powder handling processes conducted under argon gas protection. The highly automated powder circulation system significantly reduces manual intervention, lowering labor costs and minimizing operator exposure to powder. This approach aligns with the modern manufacturing industry’s demands for high efficiency and environmental sustainability. Furthermore, the efficient powder recycling system helps reduce operational costs and substantially decreases the capital investment required for production line infrastructure.

Precision Robotic Handling for High-Efficiency Production Line Operation

The robotic handling module plays a critical role in the production line by automatically performing tasks such as loading and unloading build cylinders, designated movements, and other transfer operations.

Equipped with a high-precision positioning system, BLT’s robotic handler ensures smooth and stable docking. For example, during build cylinder replacement, the module quickly removes the used cylinder and installs a new one, allowing the printing equipment to promptly begin the next job. This significantly increases production turnover efficiency and reduces machine idle time.

The BLT automated production line utilizes a rail-based robotic system that operates with high stability, further ensuring consistent performance and forming accuracy of the printing equipment. The handling system also incorporates vision recognition technology to automatically detect and avoid obstacles, preventing collisions and enhancing operational safety.

Integrated Intelligent Powder Cleaning for Streamlined Substrate Handling

Upon completion of printing, the system automatically detects that the printer has finished its task. The robotic handler then removes the build cylinder and transfers it to the post-processing module, where powder dumping, cleaning, new substrate installation, and inspection are carried out in sequence.

During the powder dumping phase, the majority of unmelted powder in the build cylinder is inverted, poured out, and recycled into the powder circulation system. In the powder cleaning stage, a dedicated robotic handler separates the substrate with the printed part from the build cylinder. Using a combination of rotation, inversion, vibration, and tapping actions, the cleaning equipment thoroughly removes residual powder from both internal and external surfaces of the part. The recovered powder is then returned to the sieving station for reuse.

Meanwhile, the robotic handler transports the separated build cylinder to the substrate installation platform, where a new substrate is mounted and inspected to ensure the cylinder meets the requirements for the next printing cycle. The qualified build cylinder is then stored in the new cylinder area. The robotic handler subsequently returns to the powder cleaning module, precisely transfers the cleaned part to the part placement area, and awaits further handling in subsequent processes.

Integrated Smart Process Control for a Highly Centralized Production System

The BLT automated production line enables end-to-end intelligent management through a centralized monitoring platform, establishing a highly integrated surveillance and control system. Equipped with multiple online monitoring cameras, the line consolidates the operational status of all modules onto a smart dashboard. Animations and live video feeds provide an intuitive display of production status, enhancing both the human-machine interaction experience and operational transparency.

The integrated control mode allows operators to switch between the control interfaces of various line units directly from the central control module screen, eliminating the need for frequent movement between equipment. This enables quick response to abnormal situations, ensuring stable, controllable, and highly efficient production operations.

Flexible Production Architecture for Forward-Looking Business Enablement

The BLT automated production line solution demonstrates high flexibility and adaptability in both layout and production capacity. The rail-based robotic handling module offers diverse layout possibilities, allowing companies to add printing equipment or other modules based on their specific capacity needs for customized configurations. The printing devices also support model replacement according to different parts and mass production requirements, meeting the diversified and complex manufacturing tasks and ensuring the scalability for future business growth.

Currently, the BLT automated production line is suitable for batch production of small parts, with potential future expansion into sectors such as aerospace, medical, and automotive to enable intelligent large-part manufacturing. BLT will continue to deepen its technological development, introduce diversified automated production solutions, and progressively advance toward the realization of true “lights-out factories,” ushering metal 3D printing into a more efficient and intelligent era.