Giant Leap for Manufacturing: Mears Machine Pioneers Large-Scale 3D-Printed Components

Indianapolis, IN – November 6, 2025 – Mears Machine Corporation is dramatically expanding the possibilities of additive manufacturing with a breakthrough capability: the production of the largest single-piece, non-welded powder bed laser components in the world. This innovation promises to reshape manufacturing across multiple critical industries, from defense and aerospace to energy and beyond.

Founded in 1966 and based west of Indianapolis, Mears Machine has long been a precision component provider for demanding applications. Their expertise, combined with a recent investment in four Velo3D Sapphire XC large-format printers, has culminated in this significant advancement. While details regarding the exact dimensions of the largest component remain confidential, company officials confirm it measures over 2 meters in diameter—significantly exceeding the build volumes of many competitors.

Beyond Size: A Paradigm Shift in Manufacturing

The implications of this breakthrough extend far beyond simply creating larger parts. Traditional manufacturing methods often require assembling multiple components, relying heavily on welding. Welding introduces potential weak points and requires extensive inspection and quality control. By producing single-piece components, Mears Machine eliminates these vulnerabilities, enhancing structural integrity and reducing the risk of failure – particularly crucial in high-stress environments.

“The ability to create complex, large-scale components in a single build unlocks a new level of design freedom and performance,” explains a company representative. “We’re seeing interest from customers looking to optimize designs, reduce weight, and improve the reliability of their products.”

Disrupting Key Industries

The impact of Mears Machine's innovation is expected to be felt most acutely in several key sectors:

• Defense & Aerospace: The demand for lighter, stronger, and more reliable components in aircraft, missiles, and other defense systems is constant. Additive manufacturing allows for the creation of complex geometries that are impossible to achieve with traditional methods, and the elimination of weld seams is a major advantage in critical applications.
• Space Exploration: Large-scale components for rocket engines, launch vehicles, and space habitats benefit significantly from the weight reduction and increased strength offered by additive manufacturing. The ability to produce complex internal structures is particularly valuable for optimizing thermal management and fuel efficiency.
• Energy (Nuclear & Oil & Gas): The harsh operating environments in these industries demand robust and reliable components. Single-piece construction minimizes the risk of corrosion and failure, while the ability to customize designs allows for optimized performance and efficiency.
• Industrial Chemical Processing: Large, complex reactors and vessels require high levels of structural integrity and corrosion resistance. Additive manufacturing provides the design flexibility and material properties needed to meet these demanding requirements.

Competition Heats Up in Large-Format Additive Manufacturing

Mears Machine is entering a competitive landscape. Several companies are vying for dominance in the large-format metal additive manufacturing space. Key competitors include SLM Solutions, EOS, and GE Additive, all offering large-format printers and related services. However, Mears Machine appears to be differentiating itself through its focus on single-piece construction and its commitment to quality and precision.

“There’s a lot of excitement around large-format printing, but simply building a large machine isn’t enough,” says an industry analyst. “It’s about mastering the entire process, from design and material selection to printing and post-processing. Mears Machine has demonstrated a strong commitment to all of these areas.”

The Velo3D Partnership: A Strategic Alliance

Mears Machine’s success is closely tied to its partnership with Velo3D. The Sapphire XC printers provide the build volume and precision needed to produce large-scale components. While the relationship appears to be a standard equipment purchase at this time, the synergy between the two companies is evident.

“Velo3D’s technology is enabling us to push the boundaries of what’s possible with additive manufacturing,” states a Mears Machine representative. “Their Flow print preparation software and Assure quality control system are essential tools for ensuring the quality and reliability of our products.”

Beyond the Hype: A Pragmatic Approach to Additive Manufacturing

While the potential benefits of additive manufacturing are well-documented, many companies struggle to realize them in practice. Mears Machine appears to be taking a pragmatic approach, focusing on applications where additive manufacturing offers a clear advantage over traditional methods.

“We’re not trying to replace traditional manufacturing,” explains a company representative. “We’re offering a complementary solution that can help our customers optimize their designs, reduce costs, and improve the performance of their products.”

The company’s commitment to quality, precision, and customer service positions it well to capitalize on the growing demand for large-scale additive manufacturing. As more companies recognize the benefits of this transformative technology, Mears Machine is poised to become a leader in the industry. The innovation isn't just about bigger parts; it’s about a fundamentally better way to manufacture, leading to stronger, more reliable, and more efficient products across a wide range of applications.

Looking Ahead

Mears Machine is currently working with several customers to develop and qualify new applications for its large-scale additive manufacturing capabilities. The company is also investing in new technologies and processes to further improve its capabilities and expand its offerings. The future of manufacturing is being forged, one large-scale, single-piece component at a time.