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Wire-Based Material Deposition
Instead of powder, metal wire is used. This simplifies material handling, storage and process control significantly.
Technology
Wire Laser Metal 3D Printing
Industrial additive metal manufacturing with wire and laser energy — WLAM, DED, LMD explained.
The Process
What is Wire Laser Metal 3D Printing?
Wire Laser Metal 3D Printing is an additive manufacturing process for metallic components. A metal wire is continuously fed, locally melted by a laser and precisely deposited. Load-bearing metal structures are created layer by layer.
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Laser Energy
The laser creates a controlled melt zone and enables precise material deposition on the component.
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Industrial Integration
The process can be integrated into robot cells, CNC hybrid systems and automated manufacturing processes.
Laser Technology
Blue Laser vs. Infrared Laser
Meltio systems use both 450 nm blue laser diodes and 976 nm infrared fiber lasers — optimised for different materials and applications.
450 nm
Blue Laser Diodes
9 × high-power diode modules
- Ideal for highly reflective metals (copper, aluminium)
- High absorptivity at short wavelengths
- Enables processing of CuCrZr, GRCop-84, Al alloys
- Multiple independent diode modules for redundancy
Best for:
Copper, Aluminium, reflective metals
976 nm
Infrared Fiber Lasers
6 × fiber-coupled laser sources
- High efficiency and beam quality
- Proven for steel, titanium, nickel alloys
- Fiber delivery for flexible integration
- Robust industrial-grade laser sources
Best for:
Steel, Titanium, Inconel, Nickel alloys
Innovation
Multi-Material in a Single Build
Meltio systems support up to 4 wire feeders simultaneously. This enables seamless transitions between different alloys within a single component — opening entirely new design possibilities.
Up to 4 Wire Feeders
Switch between materials mid-build without stopping the process.
Functional Gradients
Transition zones between materials — e.g. stainless core + wear-resistant surface.
In-Situ Alloying
Mix two wires simultaneously in the melt pool to create custom alloy compositions on demand.
Layer 1–N
Base Material
e.g. 316L Stainless
Transition
Gradient Zone
Mixed feedstock
Top Layers
Functional Surface
e.g. Stellite 6 cladding
Schematic multi-material build
Process Advantages
Why Wire-Laser DED?
Print & Repair On-Demand
Produce new components and repair worn or damaged parts using the same system and process — reducing downtime and tooling costs significantly.
Near-Net-Shape Parts
Build parts close to final geometry, then finish with CNC machining. Dramatically less material waste vs. subtractive-only machining from solid.
CNC & Robot Integration
Integrate the Meltio print head directly into existing CNC machines or robot cells — no dedicated AM machine required, protecting your capital investment.
High Material Utilization
Wire is fed only where material is needed — material utilization typically exceeds 90 %. No powder recycling, no contamination, no hazardous material handling.
Wrought-Equivalent Properties
WLAM parts exhibit mechanical properties equivalent to or exceeding wrought material — fully dense, no porosity, no internal cracks.
Large-Format Capability
Wire Laser DED is not limited by a closed build chamber. Scale to large parts by mounting the head on a gantry, CNC or 6-axis robot.
WLAM / DED / LMD
Process Variants
Wire Laser Metal 3D Printing encompasses various process variants that differ in energy source, material supply and area of application.
WLAM
Wire Laser Additive Manufacturing — the generic term for wire-based laser additive manufacturing.
DED
Directed Energy Deposition — material is specifically deposited in a melt zone. Wire laser is a subset of DED.
LMD
Laser Metal Deposition — the laser-specific designation for the targeted material deposition process.
| Criterion | Wire Laser | Powder Bed |
|---|---|---|
| Material form | Metal wire | Metal powder |
| Component size | Very good for large parts | More limited by build space |
| Typical strength | Material deposition, repair, large parts | Fine details and complex small parts |
| Post-processing | Often CNC machining for final contours | Required depending on part and surface |
| Integration | Robot cells, CNC hybrid systems | Usually standalone systems |
Materials
Materials for Wire Laser Metal 3D Printing
The specific material selection depends on the system, wire, process window, component and subsequent post-processing.
Edelstahl / Stainless Steel
Baustahl / Structural Steel
Werkzeugstahl / Tool Steel
Titan / Titanium
Nickelbasislegierungen / Nickel Alloys
Inconel
Aluminiumlegierungen / Aluminum Alloys
Kupferlegierungen / Copper Alloys
Sonderwerkstoffe / Special Alloys
FAQ
Frequently Asked Questions
WLAM stands for Wire Laser Additive Manufacturing. Metal wire is melted with laser energy and built up layer by layer into a metal component.
DED stands for Directed Energy Deposition. With the Wire Laser process, material is specifically deposited in a melt zone.
The technology is particularly interesting for companies with large metal components, expensive raw materials, repair needs, long delivery times or need for hybrid additive manufacturing.
In many cases yes. Additive build-up is often combined with CNC machining to achieve defined surfaces, fits and final contours.
Depending on component, material, tolerances and process stability, the process can be relevant for prototypes, small series and industrial applications.
Evaluate Wire Laser Metal 3D Printing for Your Company
Contact us for a technical assessment of your application.
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