Advanced additive manufacturing solutions from Meltio are proving to be transformative across multiple industrial sectors, with the company reporting significant growth in real-world applications during the first half of 2025. The wire-laser metal 3D printing technology developed by Meltio enables businesses to print and repair metal parts on demand with consistent, repeatable results.
This unique Directed Energy Deposition (DED) technology is gaining momentum in automotive, defence, aerospace, mining, oil, and gas industries by addressing critical manufacturing challenges. Companies implementing Meltio’s solutions report reduced manufacturing costs and time compared to conventional processes, successful repair of damaged components, and the ability to print obsolete parts on demand when needed.
Advanced Additive Manufacturing Applications in Automotive
The automotive industry has embraced Meltio’s DED technology for producing metal parts that must withstand extreme conditions. DMZ’s high-performance exhaust header, which has maintained its initial condition after 10,000 km on the road, demonstrates the durability of these printed components. This implementation reduced assembly time from eight hours to just one, meeting the demanding requirements of the Stellantis Group.
ERM has also leveraged this technology to develop a turbo intake manifold, printed with the Meltio M600 in dual material. This component can withstand temperatures above 800°C while reducing manufacturing costs and time by 70% compared to traditional methods.
Other automotive companies benefiting from Meltio’s technology include Iveco, which uses the Meltio Robot Cell solution at its Bourbon-Lancy plant in France to enhance design flexibility and reduce lead times, and Hirudi, which produced a stub axle achieving 62% weight reduction and 33% faster delivery.
Solving Critical Challenges in Defence and Industrial Sectors
Part obsolescence and supply chain disruptions represent significant threats to defence operations, which Meltio addresses through on-demand printing and repair capabilities. The company’s technology has enabled the production of previously irreplaceable components, such as a 300mm diffuser with improved properties and an eductor naval part for the USS Arleigh Burke (US Navy) that was replicated in less than 58 hours despite its complex requirements.
The Meltio Engine Integration for Robot arms successfully produced a closed impeller, replacing a cast bronze component with a stainless steel 316L version that offers greater strength and wear resistance in corrosive environments. These applications highlight why armed forces in the USA, Spain, France, and Korea are increasingly relying on Meltio’s capabilities for critical components.
Mining, oil, and gas industries are also benefiting from this technology by reducing supply chain delays and equipment downtime. Czech research company Roez s.r.o. has advanced energy innovation with a single-print turbine case, simplifying what was previously a complex and costly manufacturing process. According to Roez, “Meltio was the only out-of-the-box industrial wire-laser metal AM solution capable of printing multiple materials with a wide variety of options… allowing us to successfully produce a complex turbine case with internal structure—all in a single print.”
Recognition and Future Growth
The quality and innovation behind Meltio’s approach has earned industry recognition, with the Meltio M600 metal 3D printer receiving the “Enterprise 3D Printer of the Year (Metals)” award at the 3D Printing Awards 2024. The printer’s ability to work with diverse materials including copper, aluminium, stainless steels, titanium, Inconel, and nickel has revolutionised production across multiple sectors.
These are just some examples that show why armed forces like the USA, Spain, France, and Korea, in particular, and the defence sector in general, are heavily relying on Meltio’s capabilities.
“We use Meltio’s advanced additive manufacturing technology to develop innovative prototypes and specialised parts that drive energy efficiency and green solutions across nuclear, hydro, and chemical industries, supporting our mission for regional leadership and continuous innovation.”
– Feedback from ROEZ
In Japan, Daidore Corporation is a manufacturing company with a focus on agile product development and efficient production of industrial components. Faced with mounting pressure to streamline production and shorten development cycles, Daidore began evaluating advanced manufacturing technologies that could improve both productivity and product quality.
After evaluating several advanced additive manufacturing technologies, Daidore selected Meltio’s wire-laser metal deposition technology, specifically the Meltio Robot Cell, due to its unique combination of affordability, flexibility, and scalability.
“Metal Additive Manufacturing is growing in demand among the global industrial sector. It solves the needs of these customers to obtain parts and repair them, effectively and reliably, and guarantees them greater autonomy since Meltio’s equipment is installed directly in their workshops and production lines. The need for AM has never been greater and we understand those industrial customer needs.”
– Lukas Hoppe, Head of R&D at Meltio
Meltio’s advanced additive manufacturing product range continues to expand with offerings including the new Meltio M600 industrial metal 3D printer, the Meltio Engine Blue, and integration kits that transform existing CNC machines and robotic arms into hybrid manufacturing centres. Companies such as Gary Mécanique in France, ALAR in Mexico, and the Tecnológico de Monterrey have already adopted these solutions to enhance their manufacturing capabilities.
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