Producing a heat resistant
racing car part

Case study developed by ERM

Producing a heat resistant racing car part

ERM Fab&Test is one of Meltio’s trusted sales partners and it specializes in innovative solutions for additive manufacturing. It supports manufacturers, training centers and defense contractors in the integration of 3D plastic and metal technologies, from prototyping to production.

A customer from the automotive sector challenged ERM Fab&Test to produce a part for a racing vehicle that could withstand temperatures above 800 °C, with tight turnaround and cost constraints.

A demanding part for a demanding sector

A customer in the racing sector needed a metal part capable of withstanding temperatures above 800 °C. Traditional manufacturing methods were too slow and expensive for this application.

Also, machining near-net shape parts often leads to alignment challenges and increased production time due to manual repositioning and complex setups.

Meeting extreme thermal requirements with limited time and budget

The part had to be delivered quickly, offer high thermal resistance, and meet strict dimensional tolerances after post-processing. The team also needed to keep production costs low while ensuring a smooth machining workflow.

The component was printed in Inconel 718 using the Meltio M600, directly onto a 304L stainless steel base with 316L support structures. To facilitate precision machining, a custom fixture was designed. The part was then post-processed on a Tormach 1100MX, ensuring correct machining angles and efficient tool access.

This dual-material strategy enabled cost and performance optimization, only made possible thanks to Meltio’s flexible dual-wire system.

Optimised machining workflow

Increased repeatability and scalability

Reliable precision, faster setup, and seamless process flow

This use case highlights the power of hybrid manufacturing, combining Meltio’s metal 3D printing with intelligent fixturing and CNC finishing. The result is a high-performance part delivered faster and more affordably than with conventional methods.