Manufacturing a close impeller

for a fire supression system

Manufacturing a close impeller

for a fire supression system

When critical infrastructure is on the line, there’s no room for downtime. That’s exactly the case for fire suppression systems — where a single component like a closed impeller must operate non-stop to ensure the system is pressurized and ready the moment it’s needed.

For the customer, this essential part became a bottleneck: cast bronze, slow to source, and prone to wear. The solution? Reinvent it with Meltio.

Pressure never stops

Every time a fire suppression system kicks in, the impeller has to go from zero to full speed in seconds. That startup surge isn’t gentle — it forces torque through the entire system, straining every component. And that’s just the beginning.

Once running, the impeller faces constant wear from vibration, erosion, and corrosive flow. It’s not a matter of if it will degrade — just when.

From cast to custom: additive manufacturing to the rescue

Traditionally, this impeller was made in cast bronze — strong, but not ideal for today’s timelines or environments. With Meltio’s Directed Energy Deposition, the customer reimagined the impeller in stainless steel 316L, boosting mechanical and corrosion resistance.

They modified the design for printability and applied Meltio’s Radial 360 toolpath strategy, with tailored supports and variable deposition. No more molds. No long delays. Just rapid, responsive manufacturing.

Key modifications included:

Precision in two acts

The first print proved functional, though machining the complex geometry was a challenge — especially in high-strength steel. Surface quality under the supports wasn’t perfect, and rounded zones needed post-processing due to slight overgrowth.

The solution? Break the job into two print stages, adding a machining pass in between. With the Meltio positioning system, both phases stay perfectly aligned, allowing easier access to internal blades and tighter tolerances.

To optimize this:

By shifting from traditional casting to metal additive manufacturing, the customer gained more than a part — they unlocked a better process:

Minimized storage of spares

Manufacture on-site and on-demand

No delays, no stockpiles: a manufacturing evolution

By shifting from traditional casting to metal additive manufacturing, the customer gained more than just a part; they unlocked a superior process. This transition eliminated inventory backlogs and long waits for replacement parts, providing access to a better material that’s ready precisely when needed.

With Meltio, maintenance transforms into momentum, ensuring fire systems remain operational, secure, and prepared for any situation.