Meltio Materials ecosystem

Forging-level mechanical properties using commodity welding wire

Fully validated and optimized for LMD

Our process delivers high-density parts (>99.9%) with superior mechanical properties, while ensuring zero material waste: 100% of the deposited material is used in the final part.

materials-packaging-e1684880519762

Built on a open material platform

Allowing customers to use readily available welding wire to achieve outstanding mechanical performance.

Process stability & cleanliness

Wire feedstock eliminates powder handling, reducing HSE risks and simplifying material changeovers.

99,9% Densification

Fully dense components verified by CT scanning, matching or exceeding cast and wrought standards.

Single, Dual & Quad wire

Combine different metal materials in a single part. The wire-switching process is automatic, quick and clean.

Open Material Platform

Print with Meltio validated wire or certified third-party commodity wires, with no paid unlocking or licence fees.

Pre-parameterized materials for immediate industrial use

Meltio offers a portfolio of tested and validated materials, available for purchase, with ready-to-use parameters in Meltio Horizon and Meltio Space slicing software.

While Meltio Materials represent the pre-validated and fully parameterized alloys we offer, our technology is not limited to them. Customers and partners can develop and optimize new materials to gain a competitive advantage in their industries.

High absorption

The 450 nm Blue Laser Head with 9 direct laser diodes, improves energy absorption, enhancing the deposition rate across the metal material spectrum when compared to IR lasers.

Maximum efficiency

Higher energy absorption at this wavelength means less energy is needed per printed part compared to other wavelengths. This allows for a higher deposition rate with similar energy consumption to IR, resulting in a more eco-friendly and cost-efficient process.

Enhanced performance and reliability with Meltio High Power Blue Lasers

Wide-range of compatible materials

The multi-laser blue system is compatible with a broad range of metal materials, providing flexibility and versatility in production.

Integrated sensors and vision system

Real-time monitoring and feedback from integrated sensors and a vision system ensure precise control and continuous optimization during the printing process, enhancing quality and consistency.

Localized argon delivery

Optimized gas flow ensures consistent shielding and cooling, preventing oxidation and improving print quality.

Factory laser alignment

Ensures maximum printing repeatability and minimal maintenance, enhancing long-term reliability and reducing downtime.

High absorption

The 976nm infrared (IR) system, with 6 fibers lasers, delivers reliable performance for a variety of materials. While it doesn’t offer the same high absorption as newer systems, it provides consistent power and efficient deposition, ideal for repair applications.

High efficiency

The IR system balances power and efficiency, offering stable deposition speeds with low energy consumption. It remains a strong option for reliable results, especially in industrial repair.

Compatible materials

The IR system processes a variety of materials like Stainless Steels, Carbon Steels, Tool Steels, Nickel Alloys, Titanium and more. While newer systems have expanded material compatibility, the IR system excels in common industrial metals.

Reliable choice for repair works with superior versatility in multiaxis system

Superior angle of attack for repairs

The IR 1200W head is compatible with advanced slicing strategies on multiaxis systems, allowing for superior angles of attack during repairs. This flexibility enhances part orientation and precision, making it ideal for complex geometries.

Localized argon delivery

The large nozzle and effective gas ring protect against oxidation and ensure quality deposition, making it suitable for various repair tasks.

Easy to service

With low-cost, easily replaceable wear parts, such as wire nozzles and optics, the IR system keeps maintenance simple and cost-effective.

Download all Meltio Materials Datasheets

Looking to print a specific material?

Talk to an expert

Precision, density and microstructure control

Meltio’s Wire LMD process ensures parts meet or exceed traditional manufacturing standards with high density, refined microstructure, and outstanding mechanical properties.

High-quality material deposition

0.8-1.2mm welding wire: Ensures the safest, cleanest, and most reliable metal feedstock, avoiding risks associated with powder-based methods.
Option for 1.6mm wires*

Zero material waste: Every millimeter of wire is melted and deposited, eliminating unused material
and reducing waste.

Superior density and precision

99.9% relative density: Verified by CT scans and metallographic analysis, ensuring high-quality,
dense parts.

Near-net-shape precision: Parts are printed with minimal overbuilding (less than 1 mm), reducing the need for post-processing and machining.

Exceptional mechanical properties

High strength: Meltio parts offer significantly higher tensile and yield strength compared to traditional methods like casting and forging, ensuring durability in demanding applications.

Minimal porosity: Optimized laser-wire interaction ensures parts with minimal porosity, contributing to stronger, more reliable parts.

Tailored grain structure and heat treatment

Grain refinement: The rapid solidification process typically results in fine grain sizes, enhancing strength and toughness.

Post-processing with heat treatment: Heat treatments can be applied to further enhance material properties, such as reducing internal stresses, improving toughness, and refining grain structure.

Fatigue and
structural integrity

High-cycle fatigue performance matches or exceeds
that of conventionally manufactured parts.

Low residual stress: Optimized laser energy input
minimizes internal stress,
reducing warping risks.

Tested & verified by: Independent laboratories using CT scans, micrography, and tensile properties testing, among others. Check our material datasheets!

Break free from proprietary supply chains

It allows customers to explore a vast range of materials, far beyond our standard portfolio. The ability to print new materials gives businesses a unique competitive advantage, whether by improving part performance, reducing costs, or unlocking new applications.

Alongside Meltio Materials, we have successfully printed many additional materials with IR and Blue Wavelength Laser Systems, including:

Stainless Steels & Duplex Alloys​

Super Duplex 2507 – High corrosion resistance, ideal for valves and marine components.

Stainless Steel 309 & 307 – Affordable corrosion-resistant alloys for oil & gas, defense, and food industries.

Nickel & High Performance Alloys

Inconel 625, Inconel 718, Hastelloy X – Extreme temperature and corrosion resistance for aerospace, petrochemical, and energy applications.

Monel K500 – Superior mechanical and wear properties for marine and propeller shafts.

Copper & Bronze Alloys

Nickel-Aluminum Bronze (CuNiAl) – Excellent for ship propellers, oil recovery pumps, and marine valves.

Silicone Bronze (ERCuSi-A) – Used in electrical and marine components.

CuCrZr – High electrical and thermal conductivity, ideal for rocket combustion chambers and heat exchangers.

Titanium Alloys

Ti-6Al-4V (Grade 5 & Grade 23) – The industry standard for aerospace and medical implants.

Ti 5553 – High mechanical properties for motorsports and defense applications.

Tool & Hardfacing Steels

H12, H13, P20 – Used for hot work tooling, die-casting, and molding applications.

Stellite 6, Haynes 25 – High wear resistance for valves, pump components, and gas turbines.

Exotic & Specialty materials

Nitinol – Shape-memory alloy for medical and aerospace applications.

Tungsten Carbide (NiCarbW) – Used for wear-resistant coatings in mining and construction.

Pure Gold, Red Gold, White Gold – Printable for electronics and jewelry applications.

Do you need help?

Reach out! We’d love to hear about your project.

    Interested in printing a unique material?

    Talk to an expert

    Know more about us

    Check our latest news and use cases

    The benefits of a Wire-based 3D Printing Process

    Detailed technical overview of Meltio’s Wire-Laser Metal 3D Printing technology. Compare LMD vs. WAAM and SLM, review density metrics (99.99%), and analyze deposition rates for hybrid manufacturing. Learn how wire-fed directed energy deposition integrates with existing CNC and robotic systems.
    Continue reading