In the rapidly evolving field of additive manufacturing, Velo3D, Inc. (website: https://www.velo3d.com) has secured a significant intellectual property milestone with Patent Number 12697684, titled “Three-dimensional printing systems and methods of their use.” Invented by Benyamin Buller and Zachary Ryan Murphree, this patent introduces an advanced approach to laser powder bed fusion by actively managing the atmosphere within the printing chamber. By precisely controlling the internal environment, the system drastically improves the final quality of printed three dimensional objects.
The core of this invention relies on a specialized gas flow system integrated into the processing chamber. During the printing process, the system maintains a highly controlled debris concentration of 1 to 1,000 milligrams per cubic meter in the processing cone region. This airflow functions to clear gas borne debris generated when lasers melt the powder bed, ensuring that the laser beam remains unobstructed and the molten material cures properly. As a direct result, manufacturers can achieve printed parts with a porosity of 1% or less by volume, marking a substantial leap in structural integrity and reliability.
Why It Won Patent of the Month for September 2026
This technology was recognized as the manufacturing industry’s Patent of the Month for September 2026 due to its immediate potential to improve high value production sectors like aerospace, energy, and defense. Controlling porosity is one of the most persistent challenges in metal 3D printing. By effectively mitigating gas borne debris, Velo3D’s invention prevents defects that lead to part failure. The award highlights how this system transforms theoretical capabilities into a highly repeatable, production ready reality, solidifying its status as a key innovation in modern manufacturing.
R&D Tax Credit Eligibility in the USA
The practical applications of this patent offer substantial opportunities for companies to claim the Research and Development tax credit in the United States. When manufacturers implement this system to develop new 3D printed components, they often face technical uncertainties regarding optimal laser calibration, gas flow rates, or material compatibility. Engaging in a systematic process of experimentation to resolve these uncertainties, such as testing various metal alloys to achieve the sub 1 percent porosity threshold, qualifies as a research activity. Because these efforts are technological in nature and aimed at creating new or improved products or processes, the associated costs for engineering time, testing materials, and prototype development can be leveraged to offset federal tax liabilities, encouraging further domestic innovation.
