Achieving a 300mm reliable diffuser
no one could replace
Achieving a 300mm realiable diffuser no one could replace
When legacy equipment fails, replacement parts are often difficult—or impossible—to source. This was the case for a 300 mm stainless steel diffuser used in a hydraulic system. Worn down by years of operation and unavailable through traditional means, the component was brought back to life using Meltio’s unique dual-platform Directed Energy Deposition (DED) approach.
When traditional manufacturing can’t deliver
After decades of use in a hydraulic system, a 300 mm stainless steel diffuser—critical for pressure recovery at a pump’s outlet—was severely worn. Galvanic corrosion and hydraulic abrasion had thinned the walls, rendering the component unsafe for continued use.
With no OEM replacement available and traditional casting suppliers unable to fulfill low-volume production affordably, the part was considered obsolete.
Leveraging Meltio’s multi-platform capabilities
The Meltio team approached this challenge by splitting the diffuser into two main components:
Enclosed environment
The first section was printed using the Meltio M600, taking advantage of its enclosed environment and precision.
Radial 360º
The upper flange was then added using a robotic arm with Radial 360°, completing the build in stainless steel 316L.
Both stages used stainless steel 316L and off-the-shelf Meltio Horizon profiles.
Smart redesign for printability
During redesign, unnecessary features like stiffening ribs were removed—elements typically needed in cast parts but redundant in DED printing. This simplified geometry improved printability without altering the internal performance of the diffuser.
Additionally, wall thickness was increased to extend component life while keeping material costs in check.
“No casting mold, no problem. We built exactly what was needed, only where it was needed.”
By shifting from traditional casting to metal additive manufacturing, the customer gained more than a part — they unlocked a better process:
Simplification without performance loss
Geometry modification without tooling costs
On-demand production of obsolete parts
Reduced downtime, extended equipment life
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.
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: Naval
On-site, on-demand production
Material: Stainless Steel 316L
Wire feedstock proves more affordable and safer than powder-based alternatives.
Printing Time: 30h
A strategic win for critical spare parts
This diffuser is a clear example of how Meltio technology enables the on-demand production of obsolete parts, reducing downtime and extending equipment life—especially valuable in sectors where aging infrastructure meets low-volume, high-importance parts.
It isn’t just a cost-saving solution. It’s a strategic one.
Want to know more about printed parts properties?
Want to know more about printed parts properties?