The Meltio M450

Turn-key Metal 3D Printer

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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.

Designed for industry without the need for industrial infrastructure; affordable, reliable, safe, and easy to use metal 3D printer. Ideal for small to medium size part fabrication, and multi-metal 3D printing research. The Meltio M450 allows users to produce metal parts of very high density in a single-step process on a very compact footprint.

Meltio's CEO Says...

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Use 100% of the Material
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Reduce processing time by upto 80%
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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
meltio printed combustion chamber

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
meltio printed drill bit

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
meltio printed glass mold

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.

meltio m600 with open door
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.

CNC Integration
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.

meltio print head
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.
meltio manifold

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.

Meltio’s Wire-Laser 3D Printer

It allows users to produce metal parts of very high density in a single-step process on a very compact footprint.

Safe

Suitable for any environment thanks to a process built around wire, a sealed chamber and a built-in 3 stage filter.

Reliable

The metal 3D printing process is monitored in real time and compensated if required by process control.

Easy-to-use

Automatic toolpath generation and material print profiles supplied by Meltio make for a plug and play experience.

Affordable

The low capital and running costs of the Meltio M450 make metal 3D printing of conventional parts possible.

meltio horizon software

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.

Meltio horizon webinar
laser calibration system

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.

meltio materials in and out of boxes

Metal 3D Printing Experiences

Daniel Hasic

3D Printing Specialist / ROEZ


” I don’t know how much Meltio saved us, but I can tell you it saved us a lot, and then that’s why we bought the Meltio, to print this case and to reduce the cost of the machining and also reduce the cost of the raw material.

We chose the Meltio M450 as our first choice because we can print a lot of materials directly from the package.“

ROEZ is a Slovakian supplier of operating sets and investment units using a Meltio M450.

Technical Specifications

Technical Specifications
Dimensions (WxDxH): 560 x 600 x 1400 mm
Print Envelope (WxDxH): 145 x 168 x 390 mm
System Weight: :250 kg
Laser Type: 6 x 200 W direct diode lasers
Laser Wavelength: 976 nm
Total Laser Power: 1200 W
Power Input: 208 / 230 V single phase or 400 V three phase
Power Consumption: 2 – 5 kW peak depending on selected options
Process Control: Closed-loop, laser and wire modulation
Enclosure: Laser-safe, sealed, controlled atmosphere
Interface: USB, ethernet, wireless datalink
Cooling: Active water-cooled chiller included
Wire Feedstock Diameter: 0.8 – 1.2 mm
Wire Feedstock Spool: BS300
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: Under Development.
Upgrades and Accessories
Hot Wire: Programmable power supply that preheats the material to increase the deposition rate.
Dual Wire: This option allows to 3D print two wire materials sequentially with very quick wire switches.
Laser Alignment System: It allows users to calibrate Meltio’s multi-laser deposition head accurately and effortlessly prior to every print.
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