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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.
Turn a robot arm into a metal 3D printing system with no inherent size constraints. lt is the perfect platform for large and complex 3D printing, repair, cladding and feature addition. The Meltio Engine integrates with any robot arm manufacturer and interface on the market. Meltio Space slicer software for robots is compatible with ABB, Kuka, Fanuc, Yaskawa and Siemens.
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.
Large-Scale Metal 3D Printing
The Meltio Engine seamlessly integrates with robot arm manufacturers and interfaces available in the market.
Large-Scale
There are no inherent limitations when the working envelope is determined solely by the dimensions of the motion system.
Cladding
Empower any robot arm with new capabilities by transforming it into a metal 3D printing system.
Geometry Freedom
Create highly complex parts with infinite degrees of freedom.
Part Repair
Create highly complex parts with machining tolerances in the same process.
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
Miguel Peñaranda
Additive Manufacturing Engineer / K3D
"We opted for the Meltio product due to its optimal blend of high deposition rates and superior quality, perfectly suited for our current project requirements. For us, Meltio embodies the ideal equilibrium, offering both rapid deposition speeds and expansive printing capabilities without compromising on quality or resolution. K3D, a Dutch Service Bureau specializing in printing diverse parts for end-users across various industries, utilizes a Meltio M450 and Meltio Engine Robot Integration in its operations."
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 | Robot Mounted 20.5 to 23 kg |
| Printhead Size (WxDxH) | 262 x 272 x 572 mm |
| Control Unit | Wall mounted, air-cooled 80.5 kg 600 x 300 x 800 mm. Separate wall mounted 27″ HMI |
| Cooling | Water-cooled deposition head. Chiller lncluded |
| Print Envelope (WxDxH) | Depending on robot’s reach |
| 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 | 15.5 kg |
| Printhead Size (WxDxH) | 230 x 310 x 710 mm |
| Control Unit | Floor Mounted (Wheeled) 125 kg with 27″ HMI 390 x 650 x 1600 (deployed screen) |
| Cooling | Water-cooled control unit and deposition head. Chiller included |
| Print Envelope (WxDxH) | Depending on robot’s reach |
| 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 |