Industrial Wire-Laser Metal 3D printing solutions
Deploy reliable metal production on the shop floor
Plug-and-Play integration for factory environments
Meltio systems produce parts with properties comparable to those achieved through traditional manufacturing methods such as casting or forging.
Upgrade your manufacturing capabilities
Whether you’re looking for standalone systems or tailored additive manufacturing setups for industrial robots or CNC, Meltio provides the tools you need to bring your vision to life.
Turn-key Laser Systems
Industrial metal 3D printer
A compact, versatile solution for precision manufacturing on a
3-axis platform, ideal for prototyping and small-scale production.
Advanced Additive Manufacturing system
A powerful 8-axis platform for creating complex geometries and large-scale components with unprecedented freedom and precision.
Additive Manufacturing systems by our partners
Leverage Meltio’s additive manufacturing technology through our trusted partners for unique production setups.
Laser Integration Kits
Integration kit for Industrial Robots
Empower robotic platforms with advanced additive manufacturing and repairing capabilities for complex, multi-axis part production.
Integration kit for CNCs
Combine subtractive and additive manufacturing in one system for unparalleled efficiency and productivity.
Customer validation & Success stories
We tested multiple AM technologies, but Meltio’s wire-laser process was the only one that offered the density and mechanical properties of forged steel at a cost competitive enough for industrial tooling applications.
For the construction industry, downtime is the enemy. The Meltio system allows us to manufacture stainless steel replacement parts on-demand using standard wire, decoupling our maintenance schedule from global supply chain delays.
The other systems that we looked at required processing of the 3D print, which was costly to get your finished print.
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.
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.
We wanted a solution that would allow us to produce large, custom parts internally — without the overhead of tooling, molds, or external delays. Meltio’s technology, combined with robotic freedom, gave us exactly that.
We’ve opened a really unique design space through 3D printing. This project has demonstrated that additive manufacturing has the potential to produce very strong, stiff structures that will be good for marine energy.
Meltio applications
Overcome traditional manufacturing limitations, producing intricate geometries that were previously impossible or too costly to realize.
Meltio Materials: Endless possibilities
Empowering customers with unparalleled freedom in material selection.
Find your application or sector
Meltio customer
success lifecycle
Supporting every step of your metal 3D printing journey
From the initial evaluation of your application to long-term support and innovation, our team’s expertise ensures a smooth and successful experience.
Trusted by innovative companies such as
+ Technical deep dive: Wire-Laser DED vs PBF
The adoption of industrial metal 3D printers is no longer a futuristic concept; it is a baseline requirement for modern manufacturing, aerospace, and defense sectors seeking to overcome supply chain disruptions and reduce lead times. Traditional subtractive manufacturing methods involve significant material waste and extensive machining time. Meltio addresses these inefficiencies head-on with our proprietary Wire-Laser Directed Energy Deposition (DED) technology. Unlike conventional metal additive manufacturing systems that rely on hazardous and expensive metal powders, Meltio’s metal 3D printers utilize commodity welding wire. This approach ensures a clean, safe, and highly cost-effective environment while delivering fully dense, near-net-shape metal parts with exceptional isotropic mechanical properties. At the core of every Meltio metal 3D printer is our patented coaxial laser deposition head. Multiple high-power diode lasers are precisely aligned around a central wire feed. As the welding wire intersects with the laser focal point, it creates a highly controlled melt pool on the substrate or previous layer. When evaluating metal 3D printers, engineers typically compare Directed Energy Deposition (DED) with Powder Bed Fusion (PBF) and Binder Jetting. Understanding the architectural differences is critical for ROI calculations and facility planning. The versatility of a metal 3D printer is dictated by its material compatibility. Because Meltio uses standard welding wire, our users have access to an open material ecosystem, eliminating vendor lock-in. Our print profiles are rigorously tested and optimized for: Meltio metal 3D printers are actively deployed across the globe, solving complex manufacturing bottlenecks in the most demanding industries. In the aerospace sector, the buy-to-fly ratio (the ratio of raw material weight to final part weight) is a critical metric. Subtractive machining of Titanium can result in 80% material waste. Meltio's near-net-shape printing reduces this waste to near zero. Furthermore, the ability to print replacement parts on-demand or repair high-value components directly on a robotic cell provides a strategic logistical advantage for defense operations. The automotive industry leverages Meltio for rapid prototyping of engine components and the manufacturing of custom tooling and stamping dies. Utilizing dual-wire technology, manufacturers can print a part in a cost-effective steel and apply a wear-resistant hardfacing layer on critical contact points, drastically extending the lifecycle of the tooling. For independent machine shops, integrating a Meltio Engine into an existing CNC machine transforms a traditional subtractive workflow into a state-of-the-art hybrid manufacturing cell. This allows service bureaus to take on complex geometries, internal cooling channels, and multi-metal parts that were previously impossible to quote, opening new revenue streams without the footprint of a standalone PBF system. What is the maximum deposition rate of a Meltio metal 3D printer? Are the 3D printed metal parts fully dense? Do Meltio printers require a special facility setup? Can Meltio technology be used for part repair?Industrial Metal 3D Printers: What is a Metal 3D Printer and how does Wire-Laser DED work?
Metal 3D Printing Technologies: Wire-Laser DED vs. Powder Bed Fusion (PBF)
Technical Feature
Meltio Wire-Laser DED
Powder Bed Fusion (PBF)
Binder Jetting
Feedstock material
Commodity welding wire (Lowest cost, clean, zero explosion risk)
Metal powder (High cost, hazardous handling required)
Metal powder & chemical binders
Part Size scalability
Virtually unlimited (Scalable via Meltio Robot Cell)
Strictly limited by the internal build chamber volume
Limited by build box and sintering furnace size
Multi-Metal capabilities
Yes (Dual-wire capabilities for hardfacing and functionally graded materials)
No
No
Facility requirements
Standard industrial / Lab
Sealed rooms, inert atmospheres, ATEX vacuums
Printing area + dedicated debinding/sintering furnaces
High-performance materials for demanding applications
Industrial applications of Meltio systems
Aerospace and Defense
Automotive and Heavy Industry
Machine Shops and Service Bureaus
Frequently Asked Questions (FAQ)
Meltio's systems can achieve high deposition rates depending on the material and specific parameters used. For instance, when printing with standard stainless steel or titanium wire, the deposition rate significantly outpaces traditional powder-based systems, optimizing cycle times for industrial production.
Yes. Meltio’s wire-laser DED technology produces parts that are 99.97% fully dense. The microscopic structure of the printed parts exhibits isotropic mechanical properties that are comparable to, and often exceed, those of traditionally cast or forged components.
No. Unlike powder bed systems that require hazmat suits, ATEX-certified vacuums, and clean rooms due to the explosive nature of metal powders, Meltio uses safe, easy-to-handle welding wire. Our systems can be installed in standard machine shops, CNC environments, or research laboratories.
Absolutely. The Meltio Engine, especially when integrated with a Robotic Arm, is ideal for cladding, hardfacing, and repairing high-value components. The laser head can deposit new material directly onto existing worn parts, such as turbine blades or injection molds, restoring them to original specifications.
Do you need help?
Reach out! We’d love to hear about your project.