Meltio‘s leading technology – wire-laser metal 3D printing OEM solutions for worldwide industries, has been important in driving defence preparedness capabilities world-wide, as evidenced by a recent ground-breaking collaboration between the Forward Deployed Regional Maintenance Centre (FDRMC) Detachment Rota and the Spanish Armada’s intermediate-level maintenance command. This innovative cooperation successfully created crucial naval components utilising advanced additive manufacturing (AM) technology, resulting in timely readiness for the USS Arleigh Burke (DDG 51) ahead of its planned patrol across the US Sixth Fleet.
Meltio’s metal 3D printing solutions offer significant benefits for the defense sector, primarily through on-site, on-demand manufacturing of parts, enhancing operational readiness and reducing reliance on traditional supply chains. This technology allows for the creation of customized, complex components, including repairs of damaged or worn parts, leading to cost and time savings, and improved logistics efficiency.
The successful deployment of Meltio’s technology marks a watershed moment in defence manufacturing, demonstrating how sophisticated 3D printing technologies can transform military maintenance operations and improve fleet readiness in forward-deployed circumstances.
Breakthrough in Naval Component Manufacturing
The FDRMC team used Meltio’s Direct Energy Deposition (DED) technique to create two new eductors for the ship’s vacuum collecting, holding, and transfer (VCHT) system. These specialised jet pumps, which were traditionally built of cast bronze and had delivery dates of up to a year, were successfully manufactured in just seven days utilising Meltio’s cutting-edge technology.
“We have empowered and equipped our waterfront and forward-deployed engineers and maintainers that directly support our warfighters. This project executed with our Spanish allies further proves the significant readiness AM generates for our ships, restoring a critical system while meeting the compressed timeline for the ship’s forward-deployed patrol.”
– Rear Adm. Pete Small, NAVSEA Chief Engineer
What is an Eductor?
Eductors basically are jet pumps used on ships primarily to pump fluids (usually water or sludge) without the use of moving mechanical parts. They work on the Venturi principle, where a high-pressure fluid (usually seawater) flows through a narrow nozzle, creating a vacuum that draws in another fluid (like bilge water or cargo residues) and ejects the mixture out.
Technical Excellence and Innovation
Meltio’s leading technology enabled the fabrication of these intricate naval components in 316L stainless steel using its sophisticated DED system. The eductor components were created and manufactured with accuracy.
Key highlights include:
- Optimized multi-module design printed in four distinct segments – Main body (46h40m), Top fixture (8h), Suction duct (3h) and Side connection for enhanced printability and post-processing compatibility.
- Advanced printing parameters utilizing 1kW laser power, 10 mm/s feed rate, and 15 L/min argon shielding.
- All segments were designed using Meltio Space.
- Strategic material selection using corrosion-resistant stainless steel wire, proving more affordable and safer than powder-based alternatives.
- Innovative design optimization eliminating overhangs and improving printability through AM-first engineering principles.
The entire production process, from planning to installation, required approximately two months but shortened the traditional timeline by more than 80%. This success was enabled by Meltio’s advanced manufacturing systems, including the Meltio M600, demonstrating the transformative impact of Meltio’s leading technology on defence logistics.
Strategic Defence Advantages
Eductors are the hidden workhorses of naval engineering, using the Venturi effect to propel secondary fluids through high-speed primary flows. These components have no moving parts or motors, making them simple, long-lasting, and excellent for limited naval systems. However, their high wear rate and difficult inspection requirements have historically made maintenance difficult and costly.
The 3D printing technology addresses these difficulties.
- On-demand production capabilities eliminate long lead times and high costs for one-off units.
- Flexibility of digitally storing designs thus enabling rapid deployment of manufacturing capabilities anywhere from naval bases to mobile AM units.
- With these capabilities, the eductors become resilient to supply chain disruptions.
Expanding Defence Applications
This is the 37th additively produced component deployed in the Fleet since the low-risk AM approval process was introduced in 2023. The streamlined approval process of the Naval Sea Systems Command’s (NAVSEA) engineering directorate has eliminated administrative barriers, allowing for effective real-time maintenance support during forward deployments.
Meltio’s leading technology provides comprehensive solutions for defence applications through its versatile product portfolio, including the Meltio Engine for robot integration and advanced integration kits for vertical machining centers, the perfect platforms for large and complex 3D printing, repair, cladding, and feature addition operations.
Transforming Defence Manufacturing
The collaboration highlights how Meltio is revolutionising defence readiness by allowing:
- Rapid component replacement reducing critical downtime for naval vessels.
- Enhanced operational flexibility supporting maintenance operations across multiple fleets and continents.
- Cost-effective manufacturing eliminating the need for expensive moulds and long procurement cycles.
- Strategic autonomy reducing dependence on traditional supply chains for critical components.
“FDRMC is the front-line readiness generator for our forward deployed naval forces in Fifth and Sixth Fleets. Our Rota AM team attacks each maintenance window looking for a way to use advanced AM to expedite parts and solutions for our homeported and deployed ships that must be ready for Fleet tasking at a moment’s notice.”
– Capt. Mollie Bily, FDRMC commanding officer
Looking forward
This ground-breaking application of Meltio’s superior technology in defence production marks only the start of a shift in military maintenance and readiness capabilities. As the only forward-deployed RMC supporting two numbered fleets, servicing three combatant commands, and working on three continents, FDRMC’s use of Meltio’s innovative manufacturing technologies establishes a new global standard for defence logistics.
The successful fabrication of naval eductors utilising Meltio’s cutting-edge technology indicates that digital manufacturing is more than just a possibility for defence applications. Meltio is trying to usher in a new era of defence readiness by introducing the capabilities to save designs digitally and manufacturing them on-demand anywhere, at any time, literally guaranteeing that military personnel stay mission-ready despite geographical or supply chain constraints.
About Meltio Meltio is a leading provider of metal 3D printing solutions, specializing in Direct Energy Deposition (DED) technology. The company’s innovative approach to additive manufacturing enables on-demand production of complex metal components across various industries, including defence, aerospace, and industrial applications.
About FDRMC Forward Deployed Regional Maintenance Center provides emergent, intermediate, and depot-level maintenance and modernization for Forward Deployed Naval Forces in U.S. 5th and 6th Fleets through fleet technical assistance, voyage repair, contract management oversight, assessments, and diving and salvage operations.
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