How Meltio’s technology is revolutionizing the marine industry

During the 2024 RIMPAC naval maneuvers, the use of Meltio‘s hybrid metal 3D printing technology demonstrated the potential for a new era in maritime logistics. On board the USS Somerset, a San Antonio-class amphibious transport dock, the technology from Snowbird Technologies, a US distribution partner of Meltio, was used. The aim was to enable the manufacture and repair of critical components directly on board.

At the beginning of the exercise, a key component of the Somerset’s reverse osmosis pump failed. This pump, essential for drinking water treatment, is crucial for the operation of the ship. A failure would have jeopardized the mission and drastically shortened the ship’s operational time. Normally, sourcing a replacement part would take weeks or months, but with the combination of Meltio’s metal-wire laser print head and Snowbird Additive Mobile Manufacturing Technology (SAMM Tech), the crew was able to manufacture the part themselves in a matter of hours.

The technology makes it possible to turn digital models directly into physical parts. This meant that the defective component could not only be produced quickly, but also with a precise fit. One advantage of this hybrid production is the combination of additive and subtractive processes, which allows precise machining without additional post-processing.

“What we didn’t expect was that we would have the opportunity to directly help ship readiness so soon, especially for something as mission-essential as a reverse osmosis pump, where if you run out of water you’re going to be coming home pretty quick”, says Charles Wallace, Mechanical Engineer from the Naval Postgraduate School. “If the crew had to rely on a replacement part without using additive manufacturing, it would have taken weeks or months (…) With this technology, we’ll have the new component printed and ready for installation before the order for a replacement would be completed.”

The application shows how additive manufacturing can strengthen the autonomy of naval units. Ships can manufacture critical spare parts locally, reducing dependence on global supply chains and increasing operational readiness. Meltio’s approach highlights the potential to reduce costs, minimize logistical challenges and promote sustainability in military operations.