Divergent unveils Monolith One: 12 2-kW lasers for large-scale additive manufacturing
Divergent Technologies has unveiled Monolith One, a metal powder-bed 3D printer equipped with 12 2-kW lasers and a build volume of 700 x 700 x 835 mm. The machine will not be commercialized: it was designed internally to enhance the American company's proprietary DAPS production system.
The platform is over eight meters tall and six meters wide. It is designed for continuous high-productivity operations, with the goal of producing tens of thousands of munitions structures or hundreds of thousands of critical components per year.
- 12 2-kW lasers each with beam shaping technology
- Build volume: 700 x 700 x 835 mm
- Compatible materials: aluminum, nickel, steel, titanium
- Integrated powder recovery and recirculation system
- Gas flow up to 1700 m³/h
A proprietary machine for the digital factory
Monolith One is not intended for sale but represents a key element of the DAPS production chain, Divergent's adaptive system that integrates design, 3D printing, and robotic assembly.
Divergent developed Monolith One in 28 months under the guidance of CTO Brian Erhartic. The machine will not be sold or licensed to other manufacturers. This choice reflects a precise industrial strategy: maintaining complete control over the production process.
Six Monolith One units are already operational at the Torrance, California headquarters. Another 64 machines will be installed over the next two years at the new Long Beach facility, a 40,000-square-meter plant.
The production expansion will lead to an eightfold increase in annual capacity for programs serving the defense and commercial sectors.
The DAPS system: beyond 3D printing
DAPS is not just additive manufacturing. It is a platform that connects parametric design, additive production, and automated assembly to create a flexible and reconfigurable factory.
In the DAPS model, the component originates from functional requirements: mechanical loads, geometric constraints, target weight, integration with other elements. The software develops the optimal geometry, the part is printed in metal, and assembly takes place via robotic cells.
The goal is to eliminate dedicated tooling, molds, and rigid lines. The same machine configuration can produce different families of components by modifying digital files, process parameters, and operating sequences.
This approach reduces the initial costs associated with traditional molds. It is particularly advantageous in sectors such as defense, aerospace, and high-performance automotive, where production volumes do not always justify investments in conventional equipment.
Advanced laser technology and process control
The 12 2-kW lasers with beam shaping and 4-axis scanners ensure high deposition rates and precise energy control, crucial elements for the quality of metal components.
The total laser power of 24 kW enables significantly higher deposition rates than existing commercial machines. Beam shaping technology improves process stability and part quality.
The 4-axis scanners with spot size zoom capability enable precise energy positioning. This feature is essential for handling complex geometries and thickness transitions.
The gas flow system of up to 1700 m³/h supports high-energy processing and extended operating times between maintenance operations. The integrated powder recovery and recirculation system keeps material quality constant.
Monolith One can process aluminum, nickel, steel, and titanium alloys, covering the main needs of the aerospace, defense, and high-performance automotive sectors.
Industrial prospects
The installation of 70 Monolith One machines represents one of the most significant private investments in metal additive manufacturing capacity in the United States.
Lukas Czinger, CEO and co-founder of Divergent, called Monolith One “the first metal 3D printer designed from scratch for large-scale production of critical components.” He emphasized that the design incorporates years of operational experience in supplying production structures to the defense and commercial sectors.
Czinger emphasized that Monolith One is “an American machine with an American supply chain.” The Long Beach factory represents, according to the company, “the new industrial era at scale.”.
Divergent's strategy focuses on high volumes: tens of thousands of ammunition structures or hundreds of thousands of critical components per year. These figures place the initiative among the most ambitious projects for the industrialization of metal additive manufacturing.
The proprietary model raises questions about the spread of the technology. While other companies develop machines for the market, Divergent chooses full vertical integration. It will be interesting to observe whether this approach will demonstrate lasting competitive advantages in the target sectors.
article written with the help of artificial intelligence systems
Q&A
Is Monolith One available for sale?
No, the machine will not be commercialized or licensed. It is designed in-house to enhance the proprietary DAPS production system.
How many lasers does the Monolith One printer have?
Monolith One is equipped with 12 lasers, 2 kW each, with beam shaping technology. This ensures continuous high-productivity operations.
Which materials can be printed?
The machine is compatible with aluminum, nickel, steel, and titanium. It is a metal powder bed 3D printer.
Where will the Monolith One units be installed?
Six units are operational in Torrance, California. Another 64 will be installed at the new Long Beach facility over the next two years.
What is the purpose of the DAPS system?
DAPS integrates parametric design, additive manufacturing, and robotic assembly. It eliminates dedicated tooling to create a flexible factory.
