VARION
PRECISION ENGINEERING — ADAPTIVE BY DESIGN.25–50 μmRESOLUTION
±0.3%ACCURACY
99.5%DENSITY
0.1 mmWALL
WE MAKE WHAT CANNOT BE MADE.
Varion transforms intricate engineering concepts into production-ready components — lighter, stronger, and more efficient than conventional manufacturing allows.
0INDUSTRIES
0MATERIAL FAMILIES
0 μmLAYER RESOLUTION
VISION
A manufacturing capability where geometric complexity carries no penalty — where the best design wins, not the most manufacturable one.
MISSION
To compress the distance between an engineering concept and a qualified production part, so our customers ship next-generation products before their competitors finish tooling.
02
AEROSPACE & SPACE
Flow-critical components, lightweight structures
Ti-6Al-4V · LATTICE STRUCTURES · 99.5% DENSITY
03
MEDICAL & SURGICAL
Biocompatible, sterilisable, implant-grade
BIOCOMPATIBLE · STERILISABLE · Co-Cr / TITANIUM
04
SEMICONDUCTOR & ELECTRONICS
Thermal management and lattice structures
0.1 mm CHANNELS · CONFORMAL COOLING · Cu / W ALLOYS
05
ROBOTICS & AUTOMATION
Micro-mechatronics and precision motion
MICRO GEAR PROFILES · Ra 1 μm · INTEGRATED ASSEMBLIES01 — 05
FROM CONCEPT TO SERIAL.
NOT A PROTOTYPE.
A PRODUCTION PART.
FROM CONCEPT TO SERIAL.
Every part is built on qualified process parameters, inspected against the drawing, and documented — so the first article and the ten-thousandth come off the same file.
MANUFACTURING
ENVELOPE
ENVELOPEBUILD VOLUME200 × 205 × 140 mm
MAX SINGLE PART195 × 195 × 135 mm
FEATURE RESOLUTION25 – 50 μm
LAYER THICKNESS10 – 100 μm
MIN WALL THICKNESS0.1 – 0.3 mm
MIN CHANNEL Ø0.1 – 0.3 mm
DIMENSIONAL ACCURACY±0.3 – 0.5 %
SURFACE FINISHRa 1 – 5 μm
MATERIAL DENSITYup to 99.5 %
MATERIALS
- Stainless steels
- Tool steels
- Titanium alloys
- Cobalt-chromium
- Nickel superalloys
- Copper and tungsten alloys
- Technical ceramics
QUALITY & STANDARDS
DIMENSIONAL INSPECTIONCMM and optical metrology on every production batch
MATERIAL TRACEABILITYFull lot traceability from powder to finished part
DENSITY VERIFICATIONArchimedes and cross-sectional analysis
SURFACE VALIDATIONProfilometry against specified Ra
MECHANICAL TESTINGTensile, hardness and fatigue coupons per build
DOCUMENTATIONCertificates of conformance with every shipment
Components destined for medical, aerospace and defence applications are manufactured under controlled process parameters with build-level records retained for the life of the programme.
TOLERANCED TO ±0.3%.THEN WE POST-PROCESS TO TIGHTER.
INNOVATION & R&D
01
Design optimisation
We re-engineer parts for the process rather than reproducing drawings — consolidating assemblies, removing mass, and placing material only where load demands it.
02
Process development
New material and parameter sets are qualified in-house, so customers are not limited to a fixed catalogue of what we already run.
03
Applied research
We work alongside engineering teams on components that have no established manufacturing route, from feasibility through to a repeatable process.
PROCESS
CONCEPT
DESIGN OPTIMISATION
PROTOTYPE
VALIDATION
SERIAL PRODUCTION
- 01CONCEPT
- 02DESIGN OPTIMISATION
- 03PROTOTYPE
- 04VALIDATION
- 05SERIAL PRODUCTION
WHY VARION
01
DESIGN FREEDOM
Geometry that conventional processes cannot reach — internal channels, lattice structures, and assemblies consolidated into a single part.
02
SPEED TO PRODUCTION
No tooling between prototype and serial output. The same qualified file scales from one part to a production run.
03
MATERIAL BREADTH
Steels, titanium, cobalt-chromium, nickel superalloys, copper and tungsten, and technical ceramics — selected to the load case.
04
MISSION-CRITICAL QUALITY
Dimensional inspection, density verification and full build documentation supplied with every order.
FAQ
Prototype through serial production — single validation parts, low-volume batches, and ongoing production runs.
Minimum feature resolution is 25–50 μm, with wall thicknesses and internal channels down to 0.1 mm.
±0.3–0.5% as manufactured. Tighter tolerances are achieved through post-processing where the application requires it.
Yes. We also routinely propose design revisions that reduce mass or part count where the process allows it.
Stainless and tool steels, titanium, cobalt-chromium, nickel superalloys, copper and tungsten alloys, precious metals and technical ceramics.
All customer geometry, documentation and programme detail is treated as confidential and is never used for reference or promotion without written agreement.
REQUEST A QUOTEpavan@varioninc.com90224 16762
