Aerospace innovation with advanced additive manufacturing

Use case developed by CATEC

Aerospace innovation with advanced additive manufacturing

Case study developed by CATEC

Meltio continues to take metal additive manufacturing further through a new use case in collaboration with the Advanced Center for Aerospace Technologies (CATEC). This project reinforces the role of wire-laser Directed Energy Deposition (DED) as a strategic tool for advancing Spain’s aerospace sector.

Innovation in the Aerospace sector

The aerospace industry is one of the most demanding fields when it comes to quality, performance, and reliability. Every component must withstand extreme conditions while ensuring maximum safety and efficiency. To meet these challenges, CATEC has positioned itself as a European benchmark in applied research and technological development.

By incorporating Meltio’s wire-laser Directed Energy Deposition (DED) technology, CATEC is taking another step forward in its mission to bring cutting-edge solutions to aerospace manufacturing. This integration allows the center to explore new possibilities in both the production and repair of metal components, helping companies gain a competitive edge.

Driving aerospace manufacturing forward

Unlike other additive manufacturing technologies, Meltio’s solution is designed to seamlessly integrate into CNC machines, robotic arms, and standalone 3D printers. This compact and flexible approach makes it ideal for aerospace R&D environments where scalability and adaptability are key.

Some of the most relevant advantages of Meltio’s technology for aerospace include:

Proven success in other industries

This collaboration with CATEC adds to Meltio’s growing list of success stories in multiple high-performance industries:

• Automotive: Companies like DMZ and ERM have leveraged Meltio’s technology to produce exhaust manifolds and turbo components. These parts not only reduced manufacturing times and costs by up to 70%, but also endured real-world performance testing under extreme conditions.

• Defense: The U.S. Navy has successfully used Meltio to reproduce obsolete spare parts, such as a naval eductor for the USS Arleigh Burke, in less than 58 hours. Other applications include impellers and mission-critical components where downtime is not an option.

• Energy: Engineering firm Roez s.r.o. manufactured a complex turbine housing in a single piece, eliminating the need for assembly and significantly reducing lead times.

Looking ahead

The collaboration between Meltio and CATEC is a clear example of how industry and research centers can join forces to drive technological progress. By combining Meltio’s expertise in wire-laser DED with CATEC’s leadership in aerospace R&D, this alliance will open new pathways for innovation, sustainability, and competitiveness.

Meltio will continue to work closely with partners worldwide to expand the possibilities of metal additive manufacturing, ensuring that industries as critical as aerospace benefit from the efficiency, flexibility, and performance of its technology.