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Meet Our Meltio Expert
Jack Davies - Tech Expert @3DGBIRE
Jack is a technical expert in metal additive manufacturing, specialising in Meltio’s wire-laser 3D printing technology. With extensive experience in CNC and robotic integration, he helps industries unlock high-performance, cost-effective solutions using Meltio systems. Jack is passionate about advancing metal fabrication through innovative, hybrid manufacturing techniques.
The most affordable hybrid manufacturing solution, fitting almost any Vertical Machining Center in the market. Enable metal 3D printing and machining of complex geometries in a single process step. The Meltio Engine is the ideal complement for near-net shape manufacturing, repair and feature addition.
Meltio's CEO Says...
Use 100% of the Material
Reduce processing time by upto 80%
Over 50% less Wasted Material
Melito Applications
Part: Combustion Chamber
Industry: Areospace
This is the combustion chamber for a rocket engine with liquid cooling channels. Fresh fuel is flown past the combustion chamber to cool it down before it enters the engine to avoid overheating the chamber walls. This is a complex geometry that would never be made in a single-step process.
Specifications
| Size | Weight | System | Material | Gas | Layer Height |
|---|---|---|---|---|---|
| 110.5 x 110.5 x 170mm | 4.88kg | Meltio M450 | Stainless Steel 316L | Argon | 0.8mm |
Why Meltio?
- Complex Geometry
- Difficult to Machine
- Additional Design Freedom
Printing Information
| Print Time | Print Cost |
|---|---|
| 27.5 hours | 97 - 125 Euros |
Part: Mining Drill Bit
Industry: Oil and Gas
It is attached to underground drills for drilling anchor points or exploratory holes in the mining and oil and gas industry. The component wears out quickly during operations in remote sites. There is a very small area of the part which wears out, teeth and surface.
Specifications
| Size | Weight | System | Material | Gas | Layer Height | Post-processing |
|---|---|---|---|---|---|---|
| 96.5 x 96.44 x 91.3mm | 3kg | Meltio M450 | Stainless Steel 316L | Argon | 1.2mm | CNC Machining |
Why Choose Meltio?
- Lead Time
- Difficult to Machine
- Cost
Print Information
| Print Time | Print Cost |
|---|---|
| 10.5 hours | 48 - 58 Euros |
Part: Glass Mold Core
Industry: Manufacturing
Half of a mold for the glass bottle manufacturing industry. Has a fairly complicated geometry made with a difficult material to machine to ensure longer lifetimes. This part would normally be cast, therefore long lead-times and high up front investment. Meltio’s LMD process offers unparalleled flexibility and impact to the company’s bottom line in terms of part cost and lead time.
Specifications
| Size | Weight | System | Material | Gas | Layer Height | Post-processing |
|---|---|---|---|---|---|---|
| 158.5 x 79.31 x 144.3mm | 6kg | Meltio M450 | Stainless Steel 316L | Argon | 1.2mm | CNC Machining |
Why Choose Meltio?
- Lead Time
- Small Batch Production
- Using Longer Lasting Materials
- Difficult to Machine
Print Information
| Print Time | Print Cost |
|---|---|
| 24 hours | 103 - 127 Euros |
Introduction to WAAM, Powder Bed Fusion, and Meltio’s Wire-Laser Metal Deposition (W-LMD) Process
Metal additive manufacturing (AM) technologies can be broadly categorized into two main types: powder-based and wire-based processes. Among powder-based methods, Powder Bed Fusion (PBF) and Laser-Powder Directed Energy Deposition (LP-DED) are widely used. For wire-based methods, Wire Arc Additive Manufacturing (WAAM) and Meltio’s Wire-Laser Metal Deposition (W-LMD) are two leading techniques that have gained traction in industrial applications.
Powder Bed Fusion (PBF)
Powder Bed Fusion (PBF): A Powder-Based AM Process
Powder Bed Fusion (PBF) is an advanced 3D printing technology that utilizes a laser or electron beam to selectively melt metal powder, layer by layer, creating parts with high precision and intricate details. This process is ideal for producing complex geometries and is widely recognized for its excellent surface finish and mechanical properties.
Wire Arc Additive Manufacturing (WAAM)
Wire Arc Additive Manufacturing (WAAM): A Wire-Based AM Process
Wire Arc Additive Manufacturing (WAAM) is a wire-based AM technique that operates similarly to traditional welding. Using an electric arc as the energy source, it melts metal wire, which is deposited layer by layer to build large components or repair existing parts. WAAM is well-suited for producing large structural components but faces limitations with intricate geometries and surface finish quality, often requiring post-processing.
Meltio’s Wire-Laser Metal Deposition (W-LMD) Technology
Meltio’s Wire-Laser Metal Deposition (W-LMD) Technology
Meltio’s Wire-Laser Metal Deposition (W-LMD) process represents an innovative advancement in wire-based additive manufacturing. By using multiple laser beams to melt and deposit metal wire with precision, W-LMD offers significant advantages over traditional WAAM. This process concentrates heat into a small area, minimizing the heat-affected zone and resulting in better metallurgical properties, stronger parts, and higher accuracy. Meltio’s W-LMD is ideal for applications that demand complex geometries, high precision, and minimal post-processing.
Addressing WAAM Limitations with Meltio’s W-LMD
- Material Deposition Rate and Tolerances: WAAM has a high deposition rate but struggles with producing complex and detailed geometries due to poor tolerances. Meltio’s W-LMD, on the other hand, produces near-net-shape parts with higher precision and finer geometries, significantly reducing the need for post-processing and minimizing material waste.
- Mechanical Properties and Heat Management: WAAM’s high heat input can lead to larger grain structures, affecting material properties and the accuracy of the final component. Meltio’s W-LMD process operates at lower energy levels, resulting in finer microstructures and superior mechanical properties. This also reduces the risk of thermal distortion and improves overall part quality.
- Consumable Usage and Maintenance: In WAAM, consumable parts such as contact tips and nozzles require frequent maintenance due to the high heat input. Meltio’s technology, with its lower heat input and more efficient process, significantly extends the lifespan of consumables, reducing maintenance costs and increasing uptime.
- Closed Ecosystem for Seamless Integration: Unlike WAAM’s open ecosystem, where different components like robotic arms and slicer software are purchased separately, Meltio offers a fully integrated solution. Meltio’s closed system includes hardware, software, and materials that are rigorously tested and optimized for seamless integration, ensuring reliable results and reducing common issues like porosity and inconsistent material deposition.
Conclusion
While WAAM remains a valuable technology for large-scale metal additive manufacturing, Meltio’s Wire-Laser Metal Deposition (W-LMD) process offers clear advantages in terms of precision, efficiency, and part quality. By overcoming the limitations of WAAM, Meltio provides a robust solution for industries looking to enhance their metal 3D printing capabilities. With its innovative approach, Meltio’s W-LMD technology is paving the way for more reliable, cost-effective, and high-quality metal additive manufacturing solutions.
Platform for Machining and Additive Manufacturing
Compatible with nearly all CNC machines, this platform facilitates the simultaneous metal 3D printing and machining of intricate geometries within a single process step.
Hybrid Manufacturing
Produce intricate components with machining precision within a unified manufacturing process.
Retrofitting
Equip any CNC machine with enhanced capabilities by transforming it into a hybrid metal manufacturing system.
Repair
Affordable component repair, part enhancement, and additional feature integration.
Geometry Freedom
There are no inherent limitations when the operational space is solely determined by the dimensions of the motion system.
Meltio Horizon Software
Meltio Horizon is a proprietary slicer that ensures a fully tailored customer experience around our plug-and-play metal 3D printer. The Meltio M450 with its own unique features and custom-developed Meltio print and material profiles included.
Meltio Horizon
Open New DED Horizons
It’s a proprietary toolpath generator software for 3-axis metal 3D printing, tailored specifically to our wire-laser deposition process with the Meltio M450 metal 3D printer.
Laser Alignment System
The Laser Alignment System is a product developed by Meltio to aid the adoption of our state-of-the-art wire-laser deposition technology as well as to ensure print process reliability, and enhance user experience.
Meltio Materials
Meltio’s Laser Metal Deposition process achieves exceptional material mechanical properties using single wire and dual wire. Choose the ideal welding wire for your application: unlimited third-party commodity material or qualified Meltio Wire Materials that secure the user experience.
Metal 3D Printing Experiences
Francesc Martínez
R&D Integrations Director / Sivó
” If we compare with other makers of laser, with Meltio >we’ve had the clearer deposition in thousands of parts, and that is nice to see. We can also make some parts that are impossible to make without Meltio’s technology.
We can produce one part with one configuration, then another one with a total different one. Without Meltio’s technology, we wouldn’t be able to do it because the costs would be too high. “
Technical Specifications
Technical Specifications
New Meltio Blue Integration Kit
| Laser System | Blue Laser (Higher absorption and power efficiency; wider range of compatible materials than IR) 1000W 9 x 450 nm direct diode lasers |
|---|---|
| Printhead | Mounted on the right side of the spindle 32.5 to 35 kg |
| Printhead Retracted | 280 x 332 x 684 mm |
| Printhead Retracted Size (WxDxH) | 280 x 332 x 684 mm |
| Printhead Unretracted Size (WxDxH) | 280 x 332 x 943 mm |
| Control Unit | Mounted on machining center, air-cooled 80.5 kg 600 x 300 x 800 mm. 17″ HMI screen placed beside CNC controller |
| Cooling | Water-cooled deposition head. Chiller lncluded |
| Print Envelope (WxDxH) | Depending on the machining center |
| Process Control | Melt Pool Camera & Closed-loop wire modulation |
| Power Input | 200/240 V 3W+PE 380/415 V 3W+N+PE |
| Power Consumption | 9,2 kW peak 2-5 kw avg. |
Meltio Engine IR Integration kit
| Laser System | Infrarred Laser 1200W 6 x 976 nm direct diode lasers + fibers & colimators |
|---|---|
| Printhead | Mounted on the right side of the spindle 45 kg |
| Printhead Retracted Size (WxDxH) | 255 x 320 x 1075 mm |
| Printhead Unretracted Size (WxDxH) | 255 x 320 x 1135 mm |
| Control Unit | Floor Mounted (Wheeled) 125 kg with 27″ HMI screen 390 x 650 x 1600 (deployed screen) |
| Cooling | Water-cooled control unit and deposition head. Chiller included |
| Print Envelope (WxDxH) | Depending on the machining center |
| Process Control | Closed-loop, wire modulation |
| Power Input | 200/240 V 3W+PE 380/415 V 3W+N+PE |
| Power Consumption | 2 – 5 kW peak depending on selected options |