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Point of Need Manufacturing: Metal Additive Manufacturing in Defence
Modern military logistics operations face acute vulnerabilities. Extended supply chains, legacy component obsolescence, and unpredictable operational tempos demand immediate material solutions. Bringing manufacturing capabilities to the point of need is a logistical necessity.
The AM Village event at Albacete Air Force Base served as a critical touchpoint for Meltio to demonstrate its leadership in the European additive manufacturing defence sector. Organised by the European Defence Agency, the event focused on integrating additive manufacturing into military logistics through Category B projects and the Additive Manufacturing Logistic Support framework. Meltio was the most represented brand at the event, with five different operational units on the ground across the OEM team and client sites.
“Military logistics can no longer rely on waiting weeks for a replacement part. At AM Village, we proved that defence forces can bring their manufacturing capabilities directly to the front line, exactly when they need them.”
1. Addressing the challenges of legacy additive manufacturing
In recent years, defence contractors and logistics commanders have started to rely on two primary metal additive technologies, both presenting operational limitations in the field.
Selective Laser Melting requires hazardous powder handling and inert environments, while offering build volumes frequently too small for heavy defence components. Conversely, Wire Arc Additive Manufacturing (WAAM) provides sufficient scale but introduces substantial bottlenecks through complex programming requirements and extensive setup times.
Wire Laser Metal Deposition directly addresses these pain points. By using standard welding wire as feedstock, the technology eliminates powder handling risks. The Meltio M600 showed a significant operational advantage over WAAM technology, thanks to much faster programming and setup times. This acceleration is critical for immediate tactical response and containerised manufacturing solutions.
Meltio works with partners that are ITAR-registered, ensuring that its wire laser metal deposition technology meets the strict security and regulatory standards mandated by the United States government.
2. Field deployment: showing the systems' repeatability at AM Village
The objective was to evaluate system reliability, material versatility, and production speed under operational conditions. The deployment involved specific technical personnel operating distinct hardware architectures: the Meltio Robot Cell and the Meltio M600.
The systems operated continuously throughout the event, which lasted for a week. Meltio teams successfully printed over 20 unique parts using diverse materials, including various steels and aluminium, proving the technology's readiness for rugged military applications.
The operational data gathered in Albacete clarified the distinct additive manufacturing maturity levels across European defence forces. Spain has several projects ongoing, such as jet engine repair and armoured spare parts that were previously impossible to manufacture.
The French Navy has also already used Meltio for a 3D metal replacement spray plate for a ballast air compressor (DBAC), fabricated in just 5 days instead of potentially taking weeks to source through conventional Navy supply channels. This is one of several projects currently underway.
These are just two examples, but several countries already rely on Meltio's technology in one way or another for their field manufacturing capabilities. And not only in Europe: the US Navy and the South Korean Army, among others, are also working with Meltio systems.
“The introduction of Meltio's additive manufacturing (AM) into naval operations supports readiness and self-sufficiency. These printers can help the Navy overcome both obsolescence issues for ships and systems that have service lives measured in decades and directly contribute to enhanced operational availability of our systems and ships.”
- Over 20 parts printed in various steels and aluminium.
- Achieved in 5 days at AM Village.
3. Validated technical applications at the edge
The event validated the production of several critical components, showing the operational scope of the technology across three distinct logistics categories.
Combat damage repair: GDELS vehicle door axis
The team carried out a direct repair on an axis supporting the rear access door of the GDELS vehicle.
- The challenge: this component suffers constant wear because it supports a heavily weighted door. During maintenance, the thread was damaged, making assembly impossible. Traditionally, this part is manufactured by turning an oversized bar stock.
- The solution: Meltio removed the damaged area entirely, and the geometry was rebuilt in 316LSi stainless steel.
Direct combat damage repair. The total print time was precisely 41 minutes and 12 seconds, requiring only 21 minutes and 57 seconds of active laser operation.
Spare part delocalisation: Land Rover brake pedal
The deployment successfully manufactured a complete Land Rover pedal for the UK Army.
- The process: the workflow involved printing the complete main body, cutting the supports, and then adding the specific protrusions required to hook the pedal.
- Material selection: the component was manufactured in 17-4PH steel. Engineering selected this alloy for its fatigue resistance and high ultimate tensile strength. It also offers excellent corrosion protection, a vital characteristic for a component constantly exposed to mud in field operations.
Complete supply chain delocalisation for legacy components. Print time: 16h 17s in SS 17-4PH.
On-demand tooling: tank track wrench
The team produced a specialised tool used to remove tank tracks.
- The challenge: the tool is conventionally manufactured by machining, with excessive material waste, and it is subject to wear, requiring frequent replacement.
- The solution: the wrench was printed strictly on demand, directly from the digital file.
Eliminates the need for forging logistics and drastically reduces raw material waste. Print time: 58m 52s in SS 17-4PH.
4. Strategic advantages of Wire Laser Metal Deposition in defence logistics
The integration of Meltio technology into military supply chains provides definitive logistical advantages.
Operational efficiency
- 90% cost reduction. The Meltio M600 demonstrated the ability to carry out part repairs for €40 to €50, replacing the need to buy new components that are an order of magnitude more expensive.
- Rapid tactical response. Wire Laser Metal Deposition delivers significantly faster programming and setup times than other alternatives.
- Supply chain delocalisation. The technology allows forces to manufacture complete parts directly in the field, eliminating reliance on extended global supply networks.
- High exportability. Repair workflows developed for one military branch can be immediately scaled across allied nations, using the same hardware platforms.
Advanced manufacturing capabilities
- Tactical material versatility. The systems successfully process a diverse range of rugged materials natively, including various steels and aluminium grades.
- Superior metallurgical performance. Manufactured components exhibit high mechanical properties, matching or surpassing the durability of the original.
- Environmental resilience. Printed parts in materials like 17-4PH steel provide critical corrosion protection for components exposed to mud and severe field conditions.
- Resource optimisation. On-demand printing eliminates the need to stock different material formats in large quantities and prevents large quantities of material waste.
Field deployment
- Direct combat damage repair. Engineers can remove damaged sections of critical infrastructure and rebuild the exact geometry using materials like 316LSi steel, returning vehicles to operation without requiring total part replacement.
- Containerised integration. The hardware is actively being integrated into mobile, deployable containers to provide genuine point-of-need manufacturing solutions.
- Comprehensive workflow execution. The technology supports a complete logistical loop at the point of need, encompassing scanning, printing, post-processing, and final certification.
5. Expanding point of need logistics
The defence market is looking toward a full workflow requirement that includes scanning, printing, post-processing and testing at the point of need. There is a surging demand for containerised remote solutions.
The integration of Wire Laser Metal Deposition into mobile and containerised environments shifts military logistics from a predictive inventory model to an active production model. By eliminating powder hazards and optimising usability, defence forces can now secure their supply chains directly at the operational edge.
FAQs
How does Wire Laser Metal Deposition compare to WAAM for military logistics?
Meltio's technology offers a major operational advantage over Wire Arc Additive Manufacturing by requiring significantly faster programming and setup times. This ease of use allows defence personnel to deploy the technology quicker and produce parts faster in tactical environments.
Can Meltio systems be deployed in mobile or forward operating bases?
Yes. Meltio hardware is designed for point of need manufacturing. During the EDA workshop, Meltio successfully operated five different systems, including running machinery directly from a mobile unit. Meltio is also actively collaborating to integrate its systems into deployable, containerised logistical solutions.
What types of military components can be manufactured or repaired?
The technology processes a wide variety of materials, including various steels and aluminium, making it highly versatile for rugged military applications. Field applications include repairing heavy structural vehicle components like ASCOD door axes, delocalising spare parts like tactical vehicle brake pedals, and printing specialised tank maintenance tooling on demand.
This case study was originally published by Meltio as Point of need manufacturing: Metal Additive Manufacturing in Defense, written by Rubén de las Heras. Reproduced here with credit to Meltio.