Meltio Applications: Wire-Laser Metal 3D Printing in Industrial Practice
Discover the industrial applications of Meltio systems: from near-net-shape manufacturing and hybrid CNC machining to tool and shaft repair, all the way to large-scale robotic additive production.
Why Meltio for Industrial Applications?
Meltio combines 9 coaxial diode lasers with standard welding wire (DED-LB/M). This approach eliminates the typical hurdles of powder-based metal 3D printing and unlocks concrete industrial manufacturing tasks.
Standard Welding Wire
5 to 10 times more cost-effective than metal powder. Uses globally standardized welding wire (0.8 to 1.2 mm) with 100% material efficiency and zero powder waste.
Safe & Clean
No hazardous open powder handling, no ATEX explosion-proof rooms, and no special hazmat suits. Integrates directly into standard workshop environments.
Minimal Heat-Affected Zone
Focused blue diode lasers create an ultra-compact melt pool. Minimal part distortion and superior metallurgical bonding to substrates.
Build on Existing Parts
Meltio adds features directly onto existing pipes, shafts, or machined plates. Ideal for geometry additions, remanufacturing, and hybrid workflows.
10 Core Applications of Meltio Technology
From single-part repair to automated serial preforming: Discover how Meltio wire-laser systems reduce cycle times and material costs.
Near-Net-Shape Manufacturing (Near-Contour Blanks)
Wire-based build-up of massive blanks in stainless steel, titanium (Ti-6Al-4V) or Inconel 718. Drastically slashes the buy-to-fly ratio: instead of machining away up to 80% of costly material from solid blocks, near-net-shape geometry is printed and lightly finish-machined.
Tool & Die Making (Repair & Modification)
Selective build-up of hot-work tool steels (e.g. 1.2343 / H13) onto worn cutting edges, forging dies, and injection molding inserts. Design revisions and repairs succeed rapidly without purchasing costly new tool bodies.
Additive Repair & Laser Cladding
Remanufacturing of worn shafts, seal and bearing seats, turbine blades, and pump housings. Precise laser deposition minimizes thermal input and prevents distortion while ensuring 100% metallurgical bonding.
Functional Coating & Surface Cladding
Targeted cladding of corrosion- or wear-resistant alloys (e.g. Inconel 625, stainless steels) onto inexpensive carbon steel base bodies. Ideal for valves, gates, offshore, and mining components at maximum cost efficiency.
Hybrid Manufacturing (Additive + CNC Machining)
Direct integration of the Meltio deposition head into 3- or 5-axis CNC machining centres. Additive wire-laser build-up and finish milling of tolerances, sealing surfaces, and threads take place in a single setup.
Large Scale Parts with Industrial Robots
Virtually limitless envelope via 6-axis industrial robots (ABB, KUKA, FANUC, Yaskawa) plus 2-axis positioners. Production of meter-scale structural frames, flanges, tubular nodes, and vessels for heavy industry and shipbuilding.
Mechanical & Special Machinery Engineering
Production of custom brackets, bearing blocks, gear housings, and adapter fittings in small series. No tooling or foundry patterns required – slashing lead times and offering complete flexibility for custom engineering.
On-Demand Spare Part Production (MRO)
Fast production of discontinued or hard-to-source spare components directly from CAD files or 3D scans. Liberates operators from lengthy lead times, minimum order quantities, and expensive warehousing.
Aerospace & Energy Industry
Fabrication of heavy-duty components from titanium alloys (Ti64) and nickel-base superalloys (Inconel 718, 625). Dependable density (up to 99.99%) in controlled inert gas atmosphere to meet extreme mechanical criteria.
R&D, Materials Testing & Dual-Wire
Testing innovative welding wire grades, multi-material structures, and alloy transitions. The Dual-Wire system of the Meltio M600 enables switching between two materials within the same build process without setup interruption.
The Right Meltio Systems for Your Production Task
Whether standalone 3D printer, turnkey robot cell, or upgrade for existing CNC machinery: select your optimal system configuration.
Meltio M600
Standalone metal 3D printer with 300 × 400 × 600 mm build volume, dual-wire feed, inert gas atmosphere, and 9 coaxial diode lasers (1,200 W).
Meltio Robot Cell
Pre-engineered 8-axis robot cell for large components up to Ø 1,000 × 1,200 mm. Includes CE-certified laser safety enclosure and positioner.
Meltio Engine
Meltio printhead and controller as an add-on kit for existing CNC mills (Haas, DMG Mori) or articulated robots (ABB, KUKA, FANUC, Yaskawa).
Inquire Meltio System or Order Part Manufacturing?
Talk to us about your project: We advise on the right Meltio machine for your in-house production or evaluate your manufacturing inquiry on our Meltio systems.