South Korea’s Defence sector benefits from 60% lighter components

60% Lighter Components for South Korea's Defence Sector

This case study between AM Solutions and the South Korean defence sector showcases how Meltio's technology is enabling the development of lightweight, high-performance components for tactical applications. In this case, the team optimized the ice cleat (or snow pad) used on the K2 Black Panther main battle tank.

AM Solutions, one of Meltio's official partners in South Korea, specializes in delivering modular additive manufacturing systems and solutions tailored for industries like aerospace, energy, shipbuilding, and defence. As part of an R&D initiative, AM Solutions collaborated with military logistics units to drastically improve the efficiency, ergonomics, and sustainability of critical tank components using Meltio's metal 3D printing technology.

Challenging environments demand tougher solutions

K2 Black Panther tanks operate in extreme environments, especially during winter tactical missions. In these conditions, the rubber pads usually mounted on tank tracks must be replaced by metal ice cleats (snow pads) to provide grip on frozen terrain.

These metal pads, weighing nearly 12 kg per unit, create substantial physical strain for soldiers who must install or remove 30 to 50 units per vehicle within tight time constraints. The excessive weight also affects the overall operational efficiency of the tank.

A solution was needed to lighten the component while maintaining its functionality and strength under harsh conditions.

A new lightweight snow pad to solve old problems

To overcome the limitations of conventional snow pads, AM Solutions used the Meltio M600, which uses Laser Wire Directed Energy Deposition (LW-DED) technology, to manufacture and test a lightweight redesign of the component.

Using a honeycomb structure optimized for additive manufacturing, the team reduced the weight of the snow pad from 10.74 kg to 4.26 kg, a 60% reduction. The redesigned part maintained all the mechanical properties required to withstand the heavy load and stress imposed by the tank in operation.

In addition, the redesign included enhancements for terrain-specific performance by integrating features inspired by tread patterns and global case studies. The result was a structurally sound, application-optimized component, fabricated without tooling, molds, or post-processing.

• Honeycomb structure optimized for additive manufacturing.
• Weight reduction from 10.74 kg to 4.26 kg.
• Mechanical properties maintained.
• Enhancements for terrain-specific performance.
• Fabricated without tooling, molds, or post-processing.

Same functionality, greater efficiency

• Over 60% weight reduction. Minimizes the physical burden on soldiers and improves tank energy efficiency.
• No tooling required. Enables rapid prototyping and design iterations.
• On-demand production. Reduces inventory and supports real-time logistics.
• Wire-based DED process. High material utilization (up to 99%) and minimal waste.
• Repairability. Damaged parts can be selectively repaired instead of replaced.
• Scalability. Three pads produced simultaneously in one print cycle.
• Improved fuel efficiency. Around 0.64% improvement in field trials.

At a glance

• System: Meltio M600
• Sector: Defence
• Material: Stainless Steel 316LSi
• Printing time: Not disclosed (3 pads per cycle)

Adopting Meltio in the defence sector

The South Korean defence industry is advancing on two major fronts using Meltio's technology:

Digital reconstruction of legacy components.
Many parts from past generations of military equipment are no longer in production. Additive manufacturing enables cost-effective, low-volume reproduction of these critical parts.

Tactical field repair.
Through a mobile containerized solution named with:Holonic, Meltio's print head is deployed directly to the field. This enables on-site production and repair of metal components, improving readiness and responsiveness in tactical environments.

This case study was originally published by Meltio as South Korea's Defense sector benefits from 60% lighter components, featuring work by Meltio partner AM Solutions. Reproduced here with credit to Meltio.