100% Material Efficiency
Virtually every gram of fed welding wire is fused directly into the melt pool. Zero powder waste, no powder degradation, and no costly sieving or recycling steps.
Meltio Material Portfolio
Qualified Materials & Welding Wires for Meltio Systems
Meltio utilizes standard welding wire (diameter 0.8 mm to 1.2 mm) as a safe, clean, and up to 10x more cost-effective feedstock compared to metal powders.
The Wire Advantage
Why Welding Wire Instead of Metal Powder?
Unlike powder-based processes (PBF-LB), Meltio eliminates complex powder handling, explosion-proof environments, and hazardous PPE. Feedstock is fed as solid wire directly into the melt pool with zero waste.
Open Materials Platform
Meltio systems are not locked to proprietary, overpriced materials. You can utilize certified standard welding wires (MIG/MAG) from globally recognized suppliers at regular industrial market prices.
Maximum Workplace Safety
Solid metal wire is non-explosive and presents no inhalation hazard. Meltio systems operate safely in standard industrial workshop environments without cleanrooms.
Category 01
Stainless Steel Wires
The most widely used material family on Meltio systems: Excellent processability with the coaxial multi-laser head, superior corrosion resistance, and universal availability.
316L (1.4404)
Austenitic general-purpose stainless steel. Optimal corrosion resistance, biocompatible, universally qualified on Meltio.
Chemical plants, medical, food, marine
308L (1.4316)
Classic welding filler alloy. Low carbon content prevents sensitisation, ideal for weld repair.
General engineering, repair & cladding
17-4 PH (1.4542)
Precipitation hardening stainless steel. High strength after heat treatment (up to 1310 MPa Rp0.2).
Aerospace, defence, high-load components
304L (1.4307)
Standard stainless wire. High ductility, excellent weldability, cost-effective and globally available.
General use, structural parts, prototypes
ER2209 (Duplex)
Duplex stainless steel. Combines high strength with superior resistance to pitting and stress corrosion cracking.
Oil & gas, offshore components, chemical processing
Category 02
Nickel-Base Superalloys
High-temperature nickel superalloys for extreme operating conditions and corrosive media – qualified for severe thermal loads in aerospace and energy.
Inconel 718
High-strength nickel alloy for high-temperature applications up to 700 °C. Age-hardenable with superior creep strength.
Turbines, rocket engines, high-temp components
Inconel 625
Outstanding corrosion resistance from cryogenic temperatures up to 980 °C. Highly weldable on Meltio systems.
Oil & gas, offshore, exhaust systems, aerospace
Hastelloy X
Nickel-chromium-iron-molybdenum alloy with exceptional oxidation resistance up to 1200 °C and high hot strength.
Combustion chambers, gas turbine parts, industrial furnaces
Category 03
Titanium Alloys
Exceptional strength-to-weight ratio, biocompatibility, and corrosion resistance. Meltio processes titanium wires under controlled shielding gas atmospheres.
Ti-6Al-4V (Grade 5)
The most widely used titanium alloy. Two-phase α/β microstructure with excellent mechanical performance for lightweight structures.
Aerospace, motorsport, high-performance applications
CP-Titan (Grade 2)
Commercially pure titanium with outstanding corrosion resistance and biocompatibility. Ideal for chemical apparatus.
Chemical processing, marine, medical
Category 04
Carbon & Tool Steels
Economical standard welding wires for large components as well as high-strength tool steels for tooling, dies, and abrasive wear repairs.
ER70S-6 (Baustahl)
Universal, highly economical carbon steel wire. Excellent weldability, globally available at low cost. Ideal for near-net-shape blanks and large structures.
General mechanical engineering, fixtures, prototypes
H11 (1.2343)
Hot-work tool steel with high toughness, thermal shock resistance, and hot strength. Ideal for die repair and cladding.
Die casting tools, forging dies, extrusion tooling
H13 (1.2344)
High-performance hot-work tool steel with maximum wear resistance at high temperatures. Proven standard for tool modifications.
Die casting, hot forming tooling, plastic moulds
Stellite 6
Cobalt-base hardfacing alloy for extreme resistance to wear, cavitation, and erosion up to 900 °C. Ideal for laser cladding.
Valve seats, cutting tools, pump impellers, seal faces
Category 05
Copper Alloys
Superior thermal and electrical conductivity for cooling channels, heat exchangers, and aerospace propulsion – optimized for the Meltio M600.
CuCrZr (Chrom-Zirkon-Kupfer)
Precipitation-hardenable chromium-zirconium-copper alloy. Combines high electrical/thermal conductivity with elevated mechanical strength.
Rocket injectors, heat exchangers, resistance welding electrodes
Reinkupfer (Cu-OF / Cu-ETP)
Oxygen-free pure copper for maximum conductivity. Spatter-free processing on Meltio M600 using blue laser technology.
Induction coils, heat sinks, high-current electrical contacts
Category 06
Special Alloys & Open Materials
Thanks to Meltio’s open wire architecture, demanding special alloys and customer-specified welding wires can be qualified for bespoke industrial tasks.
Invar 36 (1.3912)
Nickel-iron alloy with near-zero thermal expansion coefficient. Indispensable for dimensionally stable tooling and space structures.
Precision optics, metrology, aerospace tooling
Maraging 300 (1.6358)
Ultra-high-strength maraging steel (tensile strength up to 2000 MPa after ageing). Low distortion during heat treatment.
Heavy-duty shafts, structural components, motorsport
Custom Wires on Request
Meltio supports standardized welding wires (0.8 mm to 1.2 mm) from any wire supplier. We evaluate and qualify your custom wire alloy.
Custom material qualification on Meltio systems
Materials Consultation
Would you like to inquire about a part or a Meltio system?
We assess the metallurgical feasibility of your project, evaluate material pairings, and advise objectively on welding wires, material costs, and process parameters on Meltio systems.