Formnext 2025: Meltio showcases wire-laser 3D printing for near-series metal parts

At Formnext 2025 in Frankfurt, Meltio is putting its wire-laser-based DED systems center stage. The systems process welding wire with a focused laser beam and are aimed at applications where conventional machining or casting is expensive, slow, or geometrically constrained. At the trade show, Meltio presented a wide range of production-like components from sectors such as automotive, aerospace, oil and gas, and defense.

From a technical standpoint, Meltio relies on wire-based directed energy deposition, in which material is applied layer by layer onto a substrate and then finish-machined to final dimensions. For a stub-axle prototype made of 316L, the company reports a weight reduction of 62.5 percent, 35.7 percent lower costs, and 33 percent shorter production time compared to the reference geometry. The part was printed on an M450 system in just over 21 hours with a raw weight of 3.1 kilograms. Meltio cites similar figures for a topology-optimized copper heat exchanger or a wing mold made of Invar for composite components.

In addition to single-material components, the portfolio also targets multi-material applications. For example, Meltio describes a dual combustion chamber made of Nickel 718 and a copper alloy with integrated cooling channels, as well as artillery and marine components in which stainless steel is combined with marine bronze. The parts are produced in a continuous build process that, according to the manufacturer, allows the use of different welding wires within a single job.

From the users’ perspective, the elimination of complex welding and casting processes, the reduction in tooling costs, and the ability to achieve function-driven mass savings are particularly relevant. For designers in highly regulated industries, this suggests that wire-based metal 3D printing is increasingly moving from experimental environments into robust production workflows.