Mears Machine hints at “unprecedented” large format metal AM capabilities

Mears Machine Corporation of Avon, Indiana, reported it has developed the capability to additively manufacture what it describes as the “largest single‑piece, non‑welded powder bed laser components in the world.” No image has been provided yet, and according to the company, further technical details will be released in the coming months.

James Lloyd, Chief Executive Officer of Mears Machine Corporation, is quoted as saying: “We can now deliver components with dramatically shorter lead times, reduced cost, no weld seams, and performance characteristics that often exceed traditional fabrication.” The company stated it expects the capability to be “transformational” across defense, armaments, nuclear, space, industrial chemical processing and oil & gas markets.

By eliminating weld seams and consolidating large structures into single‑piece builds, the company implies potential benefits in structural integrity, manufacturing time and cost. The claim spans multiple high‑technology sectors, suggesting broad ambition.

How Mears is embracing AM capabilities

Mears Machine Corporation was founded in 1966 and is based in Avon, Indiana, west of Indianapolis. It operates more than 100 CNC machining centres and has 250 pieces of manufacturing equipment, with an employee count of around 100. The firm’s reported revenue is approaching $50 million.

Significantly, the company has invested in large‑format metal additive manufacturing equipment. In a previous announcement, Mears Machine had acquired its third Sapphire XC metal 3D printer from Velo3D, Inc., configured for aluminum alloy Aheadd CP1. Later, the company ordered a fourth Sapphire XC machine, configured for nickel super-alloy Haynes 282.

While very large, Velo3D’s Sapphire XC build volume is not currently the largest in the industry. It is unclear at this time whether this new large-format capability stems from a software or hardware modification of its existing Velo3D machine park (in accordance with, or independently of, Velo3D), similarly to AMCM’s extension of EOS systems, or an entirely new metal PBF hardware system.

The company states that its manufacturing range spans components from 1 mm (0.040 inch) to 2 m (80 inches) in diameter, covering rotating components, casings, structures, precision parts, and large additive hardware. The firm is also certified to ISO 9001, AS9100D, and NADCAP, and is registered with the ITAR.

How large, exactly?

While the claim of “largest single‑piece, non‑welded powder bed laser components in the world” is attention‑grabbing, the announcement does not yet provide verifiable metrics such as maximum build volume, material types, mechanical properties, certification data, or production readiness timelines. Further detail will be needed to assess how this capability compares to other large‑format metal AM deployments. The company states that more information “will be released in the coming months.”

Additionally, the broad set of target markets (defense, nuclear, space, oil & gas, and chemical processing) spans highly regulated sectors, meaning qualification, certification, and repeatability will be critical for achieving commercial traction. The announcement frames the development as enabling “dramatically shorter lead times, reduced cost,” and “performance characteristics that often exceed traditional fabrication,” which are worthwhile claims but currently unquantified.

Finally, the investment in large-format metal AM and the acquisition of multiple Sapphire XC systems indicate a strategic shift for a precision-machining firm into higher-value AM services. This aligns with recent commentary suggesting that Mears Machine is positioning itself as a growth vehicle through the use of 3D printing.