Producing a temperature resistant racing car part

Producing a Temperature-Resistant Racing Car Part

Case study developed by ERM Fab&Test.

ERM Fab&Test is one of Meltio's trusted sales partners, and it specializes in innovative solutions for additive manufacturing. It supports manufacturers, training centers and defense contractors in the integration of 3D plastic and metal technologies, from prototyping to production.

A customer from the automotive sector challenged ERM Fab&Test to produce a part for a racing vehicle that could withstand temperatures above 800 °C, with tight turnaround and cost constraints.

A demanding part for a demanding sector

A customer in the racing sector needed a metal part capable of withstanding temperatures above 800 °C. Traditional manufacturing methods were too slow and expensive for this application.

Also, machining near-net-shape parts often leads to alignment challenges and increased production time due to manual repositioning and complex setups.

Meeting extreme thermal requirements with limited time and budget

The part had to be delivered quickly, offer high thermal resistance, and meet strict dimensional tolerances after post-processing. The team also needed to keep production costs low while ensuring a smooth machining workflow.

The component was printed in Inconel 718 using the Meltio M600, directly onto a 304L stainless steel base with 316L support structures. To facilitate precision machining, a custom fixture was designed. The part was then post-processed on a Tormach 1100MX, ensuring correct machining angles and efficient tool access.

Part print and support.
This process produces a virtually finished shape, ready for re-machining, in just a few hours.

Support part print.
The support part ensures precise positioning of the metal part at the desired angle in the machining center.

Part machining.
Hybridizing printing and machining reduces the number of tools required, simplifies reworking and optimizes production time.

This dual-material strategy enabled cost and performance optimization, only made possible thanks to Meltio's flexible dual-wire system.

The results

• 3x faster production compared to traditional methods.
• Optimised machining workflow.
• Cost reduction of up to 70%.
• Increased repeatability and scalability.

At a glance

• System: Meltio M600
• Sector: Automotive
• Material: Stainless Steel 316LSi + Inconel 718
• Printing time: 18h 41min

Reliable precision, faster setup, and seamless process flow

This use case highlights the power of hybrid manufacturing, combining Meltio's metal 3D printing with intelligent fixturing and CNC finishing. The result is a high-performance part delivered faster and more affordably than with conventional methods.

This case study was originally published by Meltio as Producing a temperature resistant racing car part, developed by ERM Fab&Test. Reproduced here with credit to Meltio.