LINARES, Spain, Dec 17, 2025 – Meltio used a four-show 2025 tour to highlight directed energy deposition (DED) technology for metal additive manufacturing. Through demonstrations at four global events during this year – MilAM, Rapid+TCT, EMO Hannover, and Formnext – the company provided data-driven validation that its solutions are decoupling manufacturers from fragile global logistics.
Danville Reference Site and 2025 Deployments
Meltio opened its first international reference site in Danville, VA. The company said the site supports North American defense, oil and gas, and naval users. Meltio said customers can see its hardware producing industrial parts. “Metal Additive Manufacturing is growing in demand among the global industrial sector,” said Lukas Hoppe, head of R&D at Meltio. “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.”
Meltio also reported operational deployments by defense organizations. It cited the Republic of Korea Marine Corps and the U.S. Navy, along with other defense use cases.
Defense and Operational Readiness at Milam and Rapid+TCT
Meltio said MilAM and Rapid+TCT centered on operational readiness. It said the U.S. Department of Defense (DoD) and other forces are evaluating additive manufacturing to address supply constraints.
Key defense-related items highlighted in 2025 included:
- Operational validation: A case study validated the Meltio Robot Cell in a defense setting. Technicians restored a critical shipboard reverse osmosis pump in 34 hours, faster than traditional procurement timelines.
- Lightweighting tactical gear: Meltio and AM Solutions redesigned ice cleats for K2 Black Panther. An AM honeycomb structure reduced pad weight to 4.26 kg from 10.74 kg, reducing weight 60% while maintaining mechanical integrity. This project was in collaboration with the South Korea.
- Hybrid manufacturing: With Phillips Corporation, Meltio showed the Meltio Engine Blue integrated into a Haas CNC machine. The hybrid approach targets defense manufacturing, aiming for precise metal parts, shorter lead times and less material waste.
Industrial Efficiency at EMO Hannover and Formnext
At EMO Hannover and Formnext, Meltio shifted toward industrial applications and production economics. It referenced automotive, tooling, and oil and gas use cases. Meltio cited a Hirudi stub axle case study using its Wire-Laser Metal Deposition (W-LMD) process. W-LMD is a DED approach that deposits metal wire using a laser.
Meltio reported these outcomes from the stub axle case study:
- Weight and cost: By switching to W-LMD process, the manufacturer achieved a 62.5% weight reduction and a 35.7% cost reduction versus forging cycles.
- Time: Production took more than 21 hours, with a 33% lead-time reduction.
- Adoption: Meltio said the data supports use for engine components and tooling, including by Iveco.
Oil and Gas Focus and On-Site Repair
Meltio tied its Danville site message to on-site part production and repair. It described remote or offshore operations where part delays can drive downtime. “The need for AM has never been greater, and we understand those industrial customer needs and we are clear to demonstrate to them the clear advantages of integrating Meltio wire-laser metal 3D printing solutions into the manufacturing floor and the machine shops to lower costs, increase efficiency and overcome challenges such as supply chain stability.”, explains Lukas Hoppe, head of R&D at Meltio.
- Meltio showed systems that can process Inconel 718 and stainless steel for energy applications. The company linked the capability to corrosion-resistant materials used in harsh operating environments.
- At Formnext, Meltio brought examples for Oil & Gas, including dual combustion chambers with integrated cooling channels. The company said W-LMD can meet material density and mechanical requirements for safety-critical energy infrastructure and reduce lead times.
Blue Laser Integration and Materials
Meltio highlighted the Meltio Engine Blue rollout. It said the system uses a factory-calibrated 1.4 kW blue laser. Meltio said blue laser processing improves absorption on reflective metals like copper and aluminum. It also reported a 30% reduction in energy consumption and deposition rates up to 3.5x faster than earlier generations.
At the Danville reference site, Meltio said it demonstrated multi-material capability. It listed an artillery shell and a naval propeller shaft bracket printed in Marine Bronze and stainless steel.
Source: Meltio
About Meltio
Meltio, founded in 2019 and headquartered in Linares, Spain, specializes in metal additive manufacturing solutions using its proprietary wire-laser Directed Energy Deposition (DED) technology. The company offers a range of products, including the Meltio M450 and M600 3D printers, as well as integration kits for CNC machines and robotic systems, enabling hybrid manufacturing capabilities. Meltio serves various industries such as aerospace, defense, automotive, energy, and education, providing tools for both production and research applications. As of early 2025, Meltio has sold over 500 systems worldwide, with installations in more than 60 countries, and employs approximately 120 people. Meltio’s technology has been adopted by several defense organizations, including the U.S. Navy, the French Navy, and the South Korean Army, for on-site manufacturing and repair of metal components.