Meltio Engine CNC Integration

Hybrid Additive Manufacturing

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meltio-engine-blue-integration-kit-cnc

Turn any VMC into a metal 3D printer

The most affordable hybrid manufacturing solution, fitting almost any Vertical Machining Center in the market. Enable metal 3D printing and machining of complex geometries in a single process step.

The Meltio Engine Integration kit is the ideal complement for near-net shape manufacturing, repair and feature addition.

Hybrid manufacturing

Create highly complex parts with machining tolerances in the same process.

Geometry freedom

No inherent constraints when the working envelope is only limited by the size of the motion system.

Retrofitting

Provide new capability to any CNC machine by turning it into an hybrid metal manufacturing system.

Part repair

Cost-effective component repair, part augmentation, and feature addition.

meltio-Engine-integration-kit-for-cnc

Technical specifications

Laser System: Blue Laser (Higher absorption and power efficiency; wider range of compatible materials than IR)
1000W 9 x 450 nm direct diode lasers
Printhead: Mounted on the right side of the spindle 32.5 to 35  kg
Printhead Retracted Size (WxDxH): 280 x 332 x 684 mm
Printhead Unretracted Size (WxDxH): 280 x 332 x 943 mm
Control Unit: Mounted on machining center, air-cooled 80.5 kg 600 x 300 x 800 mm. 17″ HMI screen placed beside CNC controller
Cooling: Water-cooled deposition head. Chiller lncluded
Print Envelope (WxDxH): Depending on the machining center
Process Control: Melt Pool Camera & Closed-loop wire modulation
Power Input:200/240 V 3W+PE 380/415 V 3W+N+PE
Power Consumption:9,2 kW peak 2-5 kw avg.
 
Slicer Software:Meltio relies on its Software Partners Ecosystem for the Hybrid process, including additive and subtractive
Visit Meltio Software Partners for more info
Feeder System:Quad-point traction servomotor feeder, frictionless liners
Wire Feedstock:Diameter: 0.8-1.2 mm / Spool Type: 8S300 External wire drum ready
Product Configurations:Single or Dual Wire
Compatible Materials:Stainless Steels, Carbon Steels, Tool Steels, Nickel Alloys, Titanium, Copper Alloys, Gold alloys and more
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Success stories

Meltio Engine CNC integration applications

Aircraft_Bracket_CNC
Aircraft Bracket

Titanium 64

Size: 109.6 x 160.8 x 34.8 mm

Weight:

 1.50 kg

Print time:

 13h 33′
 
semi-open-impeller
Semi-Open Impeller

Stainless Steel 316LSi + Nickel 625

Size: 73 x 48 x 17 mm

Weight:

 Stainless Steel 316LSi: 1.46 kg + Nickel 625: 0.1 kg

Print time:

 10h
Gas Turbine Blade Repair

Nickel 625

Size: 65 x 29 x 6 mm

Weight:

 0.015 kg

Print time:

 6h 16′
 
Aircraft_Bracket_CNC
Aircraft Bracket

Titanium 64

Size: 109.6 x 160.8 x 34.8 mm

Weight:

 1.50 kg

Print time:

 13h 33′
 
semi-open-impeller
Semi-Open Impeller

Stainless Steel 316L + Nickel 625

Size: 73 x 48 x 17 mm

Weight:

 0.1 kg

Print time:

 10h
Gas Turbine Blade Repair

Nickel 625

Size: 65 x 29 x 6 mm

Weight:

 0.015 kg

Print time:

 6h 16′
 
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Customer validation & Success stories

Integrating Meltio into our Haas CNC machine gave us the ability to repair complex mold geometries. We machine away the damage, print new H11 tool steel, and finish it back to original tolerance—all without moving the part.

Shop Floor Manager Tooling Services

    We use the Meltio Engine CNC to add features to existing forged shafts. This 'Hybrid' approach saves us from machining 90% of the material away from a billet. We only print the material we need, exactly where we need it." R&D Engineer Metal Forming Division

    R&D Engineer Metal Forming Division

      The Hybrid manufacturing capability is revolutionary for our pump impellers. We print the rough geometry and immediately machine it to final tolerance in the same setup. It reduced our lead time from 8 weeks (casting) to just 3 days.

      Managing Director Manufacturing Division

        The ability to 3D print stainless steel directly onboard a naval vessel allows us to maintain operational readiness at sea. Meltio’s use of standard welding wire solves the logistics problem—we don't need to carry hazardous powders, just spools of wire.

        Rear Admiral Technical Lead - US Navy

          Know more about Meltio Engine CNC integration

          webinar-unlocking-hybrid-manufacturing

          Unlocking Hybrid Manufacturing:
          Meltio Engine Blue

          Watch this webinar together with Phillips Corp. and explore how cutting-edge hybrid manufacturing technology is transforming the industry.

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