Advanced Control Module for fitting Robots and CNC
machines with our deposition technology.
The Meltio Engine Represents all the hardware and software that is required for turning an existing motion platform into a Metal AM System, allowing for the creation of scalable solutions that exceed the constraints of the M450. Producing larger series of parts additively comes with different requirements for the systems based on scale, material requirements, throughput, automation etc. Therefore, a tailor-made solution is the perfect choice for demanding applications. Work with or become an integrator for our technology.
Thanks to our wire deposition process our technology is uniquely suited for integration into CNC machining centers as it creates no powder contamination that could shorten the motion systems lifetime. Integration of the Engine in milling machines creates Hybrid systems that can switch between Deposition and Machining multiple times per part allowing for the creation of highly complex parts with machining tolerances that would be impossible to produce otherwise. Thanks to our ability to process many materials that are difficult to machine, such as titanium and Inconel and the ability to add material to existing base parts, very cost-effective strategies can be employed for component repair or feature addition.
The Engine is a complete and integrated system, that not only contains the head and the lasers, but also the electronics and software for controlling all aspects of the process, as well as accessories for integration such as the deployment system. The Deployment system is the mechanism that mounts in the CNC Tool, it holds the deposition head in a sealed enclosure when its not in use and automatically deploys it when needed. For robots we offer a similar system without the actuation that holds relevant electronics and sensors. The engine is designed to be easy to integrate in most motion systems and as such offers various levels of electrical integration depending on the Motion Controllers Capabilities. Contact us to learn about the options for your machine. The Engine offers the same systems for process control as the M450 as standard.
The Patented Deposition head forms the core of our technology. It can process both wire and powder feedstock unidirectionally by combining the output of multiple laser sources. The built in Dual Wire feed system ensures excellent control over the material flow and integrated sensors let us achieve industry leading process stability. With Good Access to all wear components and Protection for the optics the system is easy to maintain and offers a long service life.
Meltio’s LMD-WP Process Functions by precisely stacking weld beads on top of one another to create a 3D Structure. The weld bead is created when Filler material, in powder or wire form is introduced into the laser generated melt pool. Especially when processing wire, high deposition rates are achieved while keeping the heat affected zone, and thus thermal stresses in printed components low. The unique ability to process two wire materials in a single part, along with the capability of printing powder and wire materials at the same time makes our process ideal for the creation of highly complex components from demanding materials. However, thanks to its low cost of acquisition and material costs for single or dual wire operation, Meltio makes metal 3D Printing accessible for conventional parts as well.
After printing the component can directly undergo machining or surface treatment to create high precision fits, while for parts with lower tolerance requirements the component may be left as is.
Typical bead widths for wire correspond to 1.2x the material diameter, representing the lower wall thickness limit for wire 3D Printing. Powder Deposition can create thinner walls; however, this wastes some material as not all of the powder is captured in the meltpool. Therefore, we recommend to always use wire for large structures. The system can process standard MIG Filler materials, ensuring excellent availability and low material prices globally. Unlike other metal 3D Printing processes there are no limits to the maximum wall thickness of components.
Typical layer heights range from 0.3 to 1.2mm and can be selected depending on the required surface finish and printing time. Final Part Density and mechanical properties are comparable to forgings. Contact us for material testing data.
Typical "As Printed" Surface Finished. 0.5mm Layer Height
Part after polishing
The software tool chain is another core component of our technology. We offer a streamlined user experience that makes the system both accessible to new users yet offers a high customizability for our research customers, with all parameters being accessible. The touchscreen on our system provides a comfortable user interface from which all printer functions can be controlled.
Meltio supplies customers with proven printing profiles for an ever-increasing material range. Further our software is updated regularly giving customers new features throughout their machine’s lifecycle. While the updating requires a brief internet connection the printer can be used completely offline.
Due to the nature of our process, almost all weldable materials and alloys can be printed with Meltio machines and even new materials can be developed by material mixing. Please contact us if your material is not listed, as we regularly test and develop exotic materials. Standard Materials are working out of the box without any tweaking of parameters using Meltio-supplied material profiles.
Materials that are listed as under development show promise and preliminary tests have been carried out, however, the material profiles for them are not released yet. As all process parameters are accessible to customers, please contact us if your application requires one of these materials.
Note: Materials can be processed as either Powder or Wire, however, Reactive metals should always be processed as Wire for safety reasons. Price Indications are for Wire Feedstock.
A Variety of Stainless steels have been tested with our equipment, including the most common varieties such as 316L (EN 1.4404) 308L (EN 1.4316) and 304L (EN 1.4307). Approx 10 Euro / kg.
We tested a range of common steels with a range of compositions such as SAE 4140 (EN 1.7225) and A-5.18:ER 70 S-6 (EN 1.5130). Approx 8 Euro / kg.
Meltio has gathered significant experience processing nickel superalloys like Inconel 718 and Inconel 625 (EN 2.4668). Approx 57 Euro / kg.
Titanium Grade 5 (EN 3.7165) has been used extensively by us in wire form. Powder Deposition of Reactive metals like Titanium is not recommended. Approx 85 Euro /kg.