Metal 3D Printing

Turn a robot arm into a metal 3D printing system with no inherent size constraints. This metal 3D printing technology involves wire laser metal deposition (LMD) which is a directed energy deposition (DED) process that functions by precisely stacking layers of weld beads when introduced into the laser generated melt pool.  Metal wire is considered the safest, cleanest and easiest to work with metal feedstock. Print dual wire for hard-facing or anti-corrosion applications, or wire and powder to create new alloys on the fly.

This technology can drastically reduce the number of components, therefore reducing assembly time and cost. The density of Meltio metal printed parts is very comparable to a machined metal part, strength properties and various specs are also close to a machined or die cast part, making in house testing as close to the real thing as possible.

The Meltio Engine uses standard metal wire and produces clean and consistent layers. It is capable of printing stainless steels, carbon steels, titanium alloys, nickel alloys, copper and aluminium. By integrating the Meltio Engine on a robot, the high payload ensures that the system follows it’s additive toolpath precisely.      

The System

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large format printing

Offers an expansive working area for building sizable components.

near net
parts

Minimises the need for additional machining and finishing to reduce overall material usage.

Complex
Geometries

6-axis flexibility to create complex metal parts, eliminating the dependency on support structures.

dual wire
feed

Print parts using two different metal alloys, offering rapid switching between materials.

What's included

industrial robots

ROBOT

Each robot has its own characteristics and technologies. The most important of these are the range of motion and the maximum load capacity, which sets the limits of the machine’s capability. These elements allow you to choose the most suitable industrial robot.

Hardware

The Meltio wire-laser 3D printing engine allows users to produce metal parts of very high density in a single-step process on a very compact footprint. Facilitating the production of highly dense, near-net final parts with excellent strength and corrosion resistance.  

Software

Adaxis and Ai Build’s tailor made 3D printing software opens a new perspective on 3D printing, specifically for robotic systems. Optimize the performance of the integration by fine-tuning process parameters for enhanced efficiency whilst ensuring accurate printing through virtual simulation and collision checks.

safety

Our Meltio system comes with CNC Robotics tested guarding, which has been through strict risk assessments, safety standards and regulations. Panels are laser safe, doors are fitted with interlocks, whilst the guarding contains internal and external e-stops which can be monitored from an operator control panel. 

System Upgrades

Laser Alignment

This aids the adoption of the wire-laser deposition technology as well as ensuring print process reliability.

Dual Wire

Combine different metals in a single part. The wire-switching process is automatic, quick and clean.

2-Axis Positioner

One rotational and one tilting axis enables the flexible moving of workpieces, up to 1100kg payload.

Thermal Welding Camera

Monitor the metal 3D printing process from a safe position outside of the robot cell.

Applications

Prototyping

Printing a metal prototype that functions exactly like the final machined metal part is a great application of metal 3D printing. Providing an engineer with a realistic proof of concept will allow them to test a products usability and manufacturability. In house metal 3D printing requires little tooling and machining, enabling you to compress your product development cycle.

obsolete parts

Obsolete or out of stock inventory can be printed on demand from digital files in a matter of hours or days for larger parts. Where stock is no longer available, metal 3D printing gives manufacturers the ability to print critical parts onsite and on-demand. 

repair & feature addition

Metal 3D printing is extending the life span of equipment and expanding repair possibilities. Combined with 3D scanning to reverse engineer parts, repairs can lead to reduced weight and material used. 

Custom parts

Create highly intricate and complex geometries with greater design freedom utilising the robot's 6 axis. The production process allows for the manufacturing of entirely custom and unique parts tailored to specific requirements. 

Industries

aerospace

Metals can be used for printing complex structures for prototyping and manufacturing components that are lightweight, use less material and don’t require individual components to be put together.

creative

CAD modelling combined with 3D printing provides opportunities for designers to print complex geometries without the need for support material and minimal post processing. It is better suited to low volume but highly customised applications.

energy

With metal 3D printing, the design and production of parts becomes a streamlined process combining multiple parts into a single assembly and reduces the need for molds and tooling. Operators can have finished parts much quicker instead of waiting months for traditionally manufactured components.

marine

Our robotic 3D printer facilitates cost-effective, in-house prototyping, optimizing every stage of validation and significantly reducing product development cycles. The technology ensures precise and agile design testing and analysis, enabling data-driven decisions for continuous improvement.

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