South Korea’s Defense sector benefits
from 60% lighter components
Case study developed by AM Solutions
South Korea’s Defense sector benefits from 60% lighter components
Case study developed by AM Solutions
This case study between AM Solutions and the South Korean defense sector showcases how Meltio’s technology is enabling the development of lightweight, high-performance components for tactical applications, in this case, optimizing the ice cleat (or snow pad) used in the K2 Black Panther main battle tank.
AM Solutions, one of the official partners of Meltio in South Korea, specializes in delivering modular additive manufacturing systems and solutions tailored for industries like aerospace, energy, shipbuilding, and defense. As part of an R&D initiative, AM Solutions collaborated with military logistics units to drastically improve the efficiency, ergonomics, and sustainability of critical tank components using Meltio’s metal 3D printing technology.
Challenging environments demand tougher solutions
K2 Black Panther tanks operate in extreme environments, especially during winter tactical missions. In these conditions, the rubber pads usually mounted on tank tracks must be replaced by metal ice cleats (snow pads) to provide grip on frozen terrain.
These metal pads, weighing nearly 12 kg per unit, create substantial physical strain for soldiers who must install or remove 30–50 units per vehicle within tight time constraints. The excessive weight also affects the overall operational efficiency of the tank.
A solution was needed to lightweight the component, while maintaining its functionality and strength under harsh conditions.
A new lightweight snow pad to solve old problems
To overcome the limitations of conventional snow pads, AM Solutions leveraged the Meltio M600 system, which uses Laser Wire Directed Energy Deposition (LW-DED) technology to manufacture and test a lightweight redesign of the component.
Using a honeycomb structure optimized for additive manufacturing, the team reduced the weight of the snow pad from 10.74 kg to 4.26 kg, a 60% reduction. The redesigned part maintained all mechanical properties required to withstand the heavy load and stress imposed by the tank in operation.
In addition, the redesign included enhancements for terrain-specific performance by integrating features inspired by tread patterns and global case studies. The result was a structurally sound, application-optimized component, fabricated without tooling, molds, or post-processing.
Honeycomb structure optimized for AM
Weight reduction from 10.74 kg to 4.26 kg
Maintaining mechanical properties
Enhancements for terrain-specific performance
Fabricated without tooling, molds, or post-processing
Over 60% weight reduction
Minimizes physical burden on soldiers and improves tank energy efficiency
No tooling required
Enables rapid prototyping and design iterations
On-demand production
Reduces inventory and supports real-time logistics
Wire-based DED process
High material utilization (up to 99%) and minimal waste
Over 60% weight reduction
Minimizes physical burden on soldiers and improves tank energy efficiency
No tooling required
Enables rapid prototyping and design iterations
On-demand production
Reduces inventory and supports real-time logistics
Wire-based DED process
High material utilization (up to 99%) and minimal waste
Repairability
Damaged parts can be selectively repaired instead of replaced
Scalability
Three pads produced simultaneously in one print cycle
Improved fuel efficiency
~0.64% improvement in field trials
Meltio 3D Printing Solutions
Unlock the potential of metal 3D printing with Meltio. Your journey starts here.
Meltio 3D Printing Solutions
Unlock the potential of metal 3D printing with Meltio. Your journey starts here.
Same functionality, greater efficiency
To overcome the limitations of conventional snow pads, AM Solutions leveraged the Meltio M600 system, which uses Laser Wire Directed Energy Deposition (LW-DED) technology to manufacture and test a lightweight redesign of the component.
System: Meltio M600
The Meltio M600, with its built-in 3-axis probing system and work-holding solutions, is the ideal companion for your manufacturing operations.
Sector: Defense
Our technology combines safety, reliability, and easy integration. With Meltio, forces secure supply chains, extend platform lifecycles, and ensure assured availability where delay is not an option.
We partner with armed forces to secure that readiness and resilience are never compromised.
Material: Stainless Steel 316L
Wire feedstock proves more affordable and safer than powder-based alternatives.
Printing Time: Not disclosed (3 pads per cycle)
Adopting Meltio in the Defense sector
The South Korean defense industry is advancing on two major fronts using Meltio’s technology:
Digital reconstruction of legacy components
Many parts from past generations of military equipment are no longer in production. Additive manufacturing enables cost-effective, low-volume reproduction of these critical parts.
Tactical field repair
Through a mobile containerized solution named with:Holonic, Meltio’s print head is deployed directly to the field. This enables on-site production and repair of metal components, improving readiness and responsiveness in tactical environments.
Want to know more about printed parts properties?
Want to know more about printed parts properties?