Vader Systems

Vader Systems, established in 2013 by the father-son team of Scott and Zachary Vader, emerged as a notable name in the metal additive manufacturing sector. Scott Vader, a mechanical engineer with over three decades of experience in management and manufacturing, served as the CEO, while his son Zachary was the visionary behind the core technology. The inspiration for the company struck when Zachary, then 19, was unable to find a manufacturer to 3D print parts for a micro-turbine generator he was designing, leading him to develop his own metal printer. This endeavor resulted in the creation of their patented Magnet-o-Jet™ technology.

The company's business centered on manufacturing and selling metal-based industrial 3D printers. Their proprietary Magnet-o-Jet™ technology utilizes magnetohydrodynamics (MHD), which involves manipulating liquid metal through magnetism. The process melts standard metal wire feedstock in a high-temperature chamber and then uses an electromagnetic field to propel droplets of the molten metal through a nozzle, similar to an inkjet printer, to build parts layer by layer. This method offered several advantages over traditional powder bed fusion techniques, including significantly lower operational costs by using affordable wire instead of expensive specialized metal powders, faster printing speeds, and enhanced safety by avoiding hazardous powdered materials.

Vader Systems developed a product line catering to various manufacturing needs. The Vader Polaris™ was their flagship liquid metal 3D printing system. They also offered the Magnet-o-Jet™ Subsystem, designed for integration into hybrid manufacturing equipment like CNC machines, allowing for a combination of additive and subtractive processes in a single workflow. Another product was the Ares™ Microsphere Production System, which produced highly uniform spherical metal powder, which they called Vaderite™, for use in powder bed fusion systems. The company initially focused on aluminum alloys, including 6061 and 7075, with plans to expand to other materials like copper and bronze. Their target markets included heavy industry, automotive, defense, and consumer goods. In February 2019, Vader Systems was acquired by Xerox as part of the latter's strategic move into the digital and additive manufacturing market.

Keywords: Vader Systems, metal additive manufacturing, liquid metal 3D printing, Magnet-o-Jet, Scott Vader, Zachary Vader, Xerox acquisition, industrial 3D printers, magnetohydrodynamics, aluminum 3D printing, hybrid manufacturing, metal powder production, Vader Polaris, Ares Microsphere, advanced manufacturing, digital manufacturing, wire feedstock, low-cost metal printing, automotive manufacturing, defense applications