Meltio demonstrates how its metal additive manufacturing technology restores obsolete defense components quickly and cost-effectively at the point of need. Find out more > >
Part obsolescence and supply chain disruptions have become some of the greatest threats to defense operations. Meltio directly addresses these challenges with autonomous systems capable of printing and repairing components on demand at the point of need, ensuring continued readiness even when traditional supply chains fall short.
This was the case with a 300mm stainless steel diffuser from a legacy hydraulic system. The component, critical for pressure recovery at a pump outlet, had deteriorated over decades due to galvanic corrosion and hydraulic abrasion. With no OEM replacement available and casting suppliers unable to economically produce a low-volume part, it was deemed obsolete.
Meltio’s unique dual-platform Directed Energy Deposition process offered a solution. The diffuser was redesigned and split into two segments. The main body was printed using the Meltio M600 in a controlled environment, while the upper flange was added with a robotic arm using the Radial 360 process. Both stages used stainless steel 316L and standard Meltio Horizon profiles. Nonessential features were removed and wall thickness increased to boost durability without increasing material costs.
Meltio’s ability to simplify geometry, avoid tooling costs, and produce improved legacy parts on demand was also demonstrated in the redesign of an eductor part for the USS Arleigh Burke. This high-wear naval component was traditionally difficult to inspect and slow to replace. With a new design and material, Meltio reproduced it in less than 58 hours.
These examples underscore Meltio’s strategic value, enabling rapid, cost-effective production of mission-critical parts when and where they are needed most.
