Meltio highlights defence sector applications for its wire-laser DED technology
July 2, 2025
Meltio, based in Linares, Spain, has reported on the use of its Directed Energy Deposition (DED) Additive Manufacturing technology in defence sector applications. A major challenge for military readiness, the company notes, is the failure of legacy components, particularly those that are no longer manufactured or are difficult to source. Additive Manufacturing offers an effective solution to this problem.
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By harnessing its wire-laser-based DED, Meltio is offering the defence industry a new approach to maintenance, repair, and production of essential components – delivering solutions that it says are faster, smarter, and built for resilience.
The issue with legacy parts and supply chain fragility
From impellers and diffusers to eductors and structural parts, many components used in military and defence applications are often decades old. Traditional manufacturing methods, such as casting or subtractive machining, struggle to keep pace, especially when the original designs or tooling are lost. Replacement parts have long lead times or are cost-prohibitive.
Enhancing operational availability with Meltio’s technology
Meltio’s DED machines, including the Meltio M600 metal AM machine and the robotic and CNC integration kits, allow defence users to manufacture complex metal parts on-demand, on-site, and with minimal redesign.
The result is a significant shift in how parts are sourced, repaired, and even improved.
Stainless steel diffuser
To highlight real-world scenarios, Meltio provided the example of a stainless steel diffuser, essential for pressure recovery at a pump outlet. It was rendered inoperable after years of hydraulic abrasion and galvanic corrosion. No manufacturer could reproduce it affordably or quickly.
Meltio’s technology enabled the Additive Manufacturing of the component in two parts, simplifying the build and allowing for improved wall thickness and mechanical performance. Redundant features were removed, and internal geometries were preserved.
Eductor
A further example is that of eductors. These components are a type of pump that uses the venturi effect to create a vacuum and move air, gas or liquids. They are often cast in CuSn or CuNi alloys, but wear quickly and are challenging to inspect or replace predictively.
Meltio helped reimagine the eductor, additively manufacturing it in 316L stainless steel. The new design featured optimised sub-components for post-processing and a second-generation model specifically tailored for AM.
Closed impellers
Fire protection systems rely on closed impellers that spin constantly. In traditional cast bronze, these parts face vibration, cavitation, and corrosion, often leading to sudden failure.
Meltio’s additive approach rebuilt the impeller in 316L stainless steel, using a Radial 360 build strategy with custom supports.
