Military maintenance and logistics face persistent challenges in sourcing spare parts for ageing systems, where obsolete components and long procurement delays threaten operational readiness. This issue is especially acute with older equipment such as pump assemblies and naval ship systems, where original casting molds or technical drawings may no longer exist, and traditional supply chains prove cumbersome and slow. To address these critical gaps, defence forces are increasingly embracing additive manufacturing technologies, with Meltio’s metal 3D printing solutions emerging as a prominent example of this shift toward on-demand, localised production.
Meltio’s technology centres on Directed Energy Deposition (DED) via a wire-laser process, capable of integration with robotic arms and CNC machinery, enabling function-critical metal parts to be manufactured directly at the point of need. Such flexibility is invaluable in naval shipyards, mobile maintenance facilities, and logistics hubs. The use of standard, durable materials—like 316L stainless steel—yields parts with enhanced corrosion resistance and mechanical strength compared to traditional bronze or copper alloys, promising greater longevity in harsh operational environments.
One practical application includes the reproduction of a stainless steel diffuser, which had deteriorated through galvanic corrosion and wear. Conventional remanufacture was cost-prohibitive and slow, but by leveraging Meltio’s layered printing techniques, the component was rebuilt in two stages with geometric optimisation and adjusted wall thickness for superior performance. Similarly, components such as ejectors and impellers for fire extinguishing systems have been redesigned and produced additively, benefiting from tailored printing strategies like radial paths and segmented builds with intermediate machining to ensure tight dimensional accuracy and functional reliability.
The operational benefits of this approach are being recognised worldwide. The United States and South Korean armed forces report substantial reductions in repair times and marked improvements in equipment availability. The South Korean Marine Corps notably became the first in Asia to validate Meltio’s robot-assisted metal 3D printing, adopting the technology for in-house production of discontinued parts—a step that strengthens field operability and cuts costs. This endorsement reflects a wider trend towards decentralised manufacturing autonomy within defence sectors traditionally reliant on extended supply chains.
Further validation comes from prestigious endorsements by international military bodies. The U.S. Department of Defense has formally recognised Meltio as a strategic technology partner, a significant accolade that underscores the company’s unique contributions to addressing logistical challenges through patented metal 3D printing methods. The French Navy has also experimentally deployed Meltio’s technology aboard the aircraft carrier Charles de Gaulle during the ‘Ursa Minor’ exercise, demonstrating reliable on-site repair and manufacturing capabilities under operational conditions.
Most recently, Meltio’s technology proved its operational relevance during the 2024 Rim of the Pacific (RIMPAC) exercise, where it was employed to produce a critical reverse osmosis pump part for the USS Somerset. Managed by Snowbird Technologies, this intervention highlighted the capacity of additive manufacturing to effectively resolve equipment failures in the midst of complex naval operations, further affirming the strategic value of Meltio’s approach.
Collectively, these advancements mark a significant evolution in defence logistics—from reactive, supply chain-dependent maintenance towards proactive, locally-driven manufacturing resilience. By enabling armed forces to produce and repair metal components on-demand, Meltio’s additive manufacturing technology is not only solving immediate spare parts scarcity but also shaping the future of operational readiness and strategic autonomy in military contexts worldwide.
Source: Noah Wire Services
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