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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.
Enhance your manufacturing potential by integrating blue lasers, a spacious build area, and a fully inert chamber to optimize material properties. With enhanced process control, advanced sensors, and real-time monitoring, printing has never been more effortless, enabling you to maintain consistent production round the clock.
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.
Discover the Meltio M600, a cutting-edge metal 3D printer transforming additive manufacturing. With its multi-material capability and laser-based deposition technology, the M600 ensures high-quality, precise metal parts with minimal waste. Perfect for prototyping and custom parts, its user-friendly interface and compact design make it ideal for any production environment.
The All-in-one Printing Platform.
The Meltio M600 enables the printing of either large parts or a series of small parts in succession, all at once. It offers enhanced process control to ensure stability and repeatability throughout the printing process.
Production Ready
Larger components, increased deposition speed, broader material compatibility, inert printing environment, reduced maintenance requirements, and integrated work holding solutions.
Easy to Use
Reduced operator involvement due to advanced sensor technology, user-friendly interface, specialized slicing software, and zero-point clamping system.
Reliable
Improved wire feeding mechanism, fiber-free deposition nozzle, upgraded process control systems, and a host of additional functionalities.
Reduced Maintenance
The newly engineered deposition head eliminates the necessity for laser alignment, while enhancements to the motion system guarantee optimal longevity.
Blue is the new green.
The Meltio M600 allows to printing of large parts or a batch of small parts in a row, simultaneously. Improved process control for stability and repeatibility.
Blue Light
Light with a wavelength of 450 nanometers enhances energy absorption and increases printing efficiency across the spectrum of metal materials.
No Calibration
It comes pre-aligned from the factory to ensure optimal printing repeatability and minimal maintenance requirements.
Hotwire Compatible
The deposition head is designed to be used with an optional hotwire supply, enhancing the deposition rate and expanding the range of materials that can be processed.
High Efficiency
Significant reduction in energy consumption per component leads to a more environmentally friendly and cost-effective process.
Software Partner Ecosystem
Meltio Horizon, our exclusive slicer, provides a personalised experience for our plug-and-play metal 3D printer, the Meltio M450. It comes equipped with custom-developed Meltio print and material profiles, tailored to the printer's unique features.
Meltio Materials
Meltio's Laser Metal Deposition process delivers outstanding material mechanical properties, utilising both single and dual wire options. Choose the perfect welding wire for your specific application: from a limitless array of third-party commodity materials to Meltio Wire Materials, ensuring a secure user experience.
Technical Specifications
Technical Specifications
| Dimensions (WxDxH): | 1050 x 1150 x 1950 mm |
|---|---|
| Print Envelope (WxDxH): | 300 x 400 x 600 mm |
| System Weight: | 800-1000 kg (depending on options) |
| Movement System | Servo Motor Linear axis with Absolute encoder on all axis |
| Filtration System | 3 Stage Particulate and Chemical Filtration included |
| Environmental Control | Control O2 and Humidity level |
| Laser Type: | 9x Direct Diode Lasers |
| Laser Wavelength: | 450 nm (blue) |
| Total Laser Power: | 1000 W |
| Power Input: | 400 V Three Phase |
| Power Consumption: | 4 – 6 kW Peak depending on selected options |
| Process Control: | Closed-loop, Laser and Wire Modulation |
| Touch Probe | Automated XYZ Touch Probe integrated |
| Enclosure: | Laser-safe, Controlled inert atmosphere |
| Interface: | USB, Ethernet, WiFi |
| Cooling: | Active water-cooled chiller included |
| Wire Feedstock Diameter: | 0.8 – 1.2 mm |
| Wire Feedstock Spool: | BS300 or Wire drums |
Wire Materials
| Stainless Steels: | Excellent strength and corrosion resistance. |
|---|---|
| Mild Steels: | Cheap and ductile, with unparalleled machinability and weldability. |
| Carbon Steels: | High impact strength, retain hardness at high temperatures. |
| Titanium Alloys: | Highest strength to weight ratio and corrosion resistance. |
| Nickel Alloys: | High versatility, outstanding heat and corrosion resistance. |
| Copper & Aluminum: | Conductivity and corrosion resistance & lightweight strength. Parameters under development |
Upgrades and Accessories
| Hot Wire | Programmable power supply that preheats the material to increase the deposition rate |
|---|---|
| Exteral Wire Drum Connection | Connect external wire drums to the M600, allowing the use of 100kg and 200kg material packs |
| Multi-wire | :This option allows for sequential 3D Printing of up to 4 materials with very fast automatic wire switches |
| Zero Point Clamping System | Accurately and quickly couple fixture plates to the print bed of the M600 for production |