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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.
An affordable turn-key solution powered by the Meltio Engine Integration kit for Industrial Robots. It is designed to provide industries with a secure and efficient solution for manufacturing metal 3D printed parts. The Meltio Engine Robot Cell is the most versatile and capable solution for 3D printing, repair, cladding, 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.
Plug and Play Installation
It’s the perfect platform for large and complex 3D printing, repair, cladding, and feature addition.
Plug and Play Installation
Allows the customer to receive a ready to use cell for robotic metal 3D printing.
Best Components
Robot and positioner on a self-supporting platform, laser safe enclosure.
Safe, Tested and Certified
CIn accordance with European CE and laser safety regulations and multiple quality controls.
Focus on Printing
On-site training for enabling the end user to be successful with Meltio and develop applications in short time.
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
| Dimensions (WxDxH) | 4.050 x 2.350 x 3.000 mm. Indoor use only |
|---|---|
| Print Envelope | 1 meter diameter printing volume with continuous positioner axes interpolation. Actively Cooled 300x400 mm build platform |
| System Weight | 4000kg |
| Laser System | Meltio Engine Robot - Laser Integration Kit |
| Platform | Structural Steel with Laser-safe Class 1 enclosure with CE certification. All equipment anchored to the platform |
| Robot System | ABB 6- Axis Robot Arm & 2-Axis Workpiece Positioner |
| Integration | Unified Control Panel, 4k WebCam monitoring & Live Timeline of sensors and 3D model based on reading TCP positions from robot |
| Slicing software | Meltio Space one year subscription included. Pre-defined Print profiles and slicing strategies. Focused on ease of use |
| Power Input | 385-415V 50/60Hz (3W+N+PE) 20kw peak 7kw avg. upon request: 230V 50/60Hz (3W) |
| Required Inputs | Inert Argon Gas supply between 2 to 5 bar. (Meltio offers an optional Gas Regulator) & Internet Lan cable connection |
| Accessories | Inert Bubble for full Print envelope with Independent Atmospheric Control O2 and Humidity and Temperature Monitoring |