Intuitive plug-and-play solution for large format metal 3D printing

Meltio’s Robot Cell is a turnkey solution, which contains the Meltio Engine integrated on an industrial robot. The system is a cost effective, plug and play solution, for printing highly accurate and fully dense metal parts. Offering a great deal of advantages over traditional methods, the system allows the customer to print at large scale by utilizing the large working envelope of the 6 axis robot. This large format metal 3D printer also gives you the ability to perform non planer extrusion, by synchronising the robot and rotational positioner you are able to print non planar and complex geometries.

Perhaps the biggest advantage of the Meltio Robot integration is the potential to print near-net parts – meaning 3D printed parts are very close to the final desired shape and dimension. By reducing the amount of material that needs to be removed or processed, near net shape manufacturing can significantly reduce the time and cost associated with 3D printing as a consequence of the reduction in the wastage of raw material and energy.

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. Using a directed energy deposition method, a laser is used to melt and fuse the material as its deposited layer by layer. By integrating the Meltio Engine on a robot, the high payload ensures that the system follows the additive toolpath precisely. 

As the integrator, CNC Robotics focuses on the installation, training and safety of the system. We train users on how to use the system as well as completing a site acceptance test (SAT) enabling you to focus on developing 3D printing applications and manufacturing parts in short time.

The System

Enclosed safety cell

Features a laser-protected cell to safeguard operators during the 3D printing.

All in one
interface

Equipped with a powerful on-board computer to facilitate model cutting and access to process parameters.

Dual wire
feed

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

near net
parts

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

What's included

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

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

safety

The Meltio Robot Cell comes with a standard enclosure which allows safe operation and quick installation. All cell controls are unified on a single control panel, giving you simple control of the doors, emergency stops and robot operations. The cell is laser safe and incorporates the robots native safety program to avoid collisions. 

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

High resolution near net shapes

This advanced technology is capable of achieving remarkably high resolutions, particularly for intricate and small features. By employing a layer-by-layer approach to selectively add material, it effectively minimizes material waste, distinguishing itself from conventional manufacturing methods.

Laser Cladding

This process involves depositing a thin layer of material onto a substrate using a focused laser beam, offering precise control over the coating thickness. The technique is employed to impart characteristics such as wear resistance, corrosion resistance, and improved thermal conductivity to critical parts. By selectively adding material where it is needed, laser cladding ensures targeted reinforcement, extending the service life of components and reducing the need for full replacements.

Large and complex parts

Meltio allows for the creation of large and intricate structures with high precision. This capability is invaluable in industries like aerospace, where large aircraft components, such as wing sections or engine parts, require both structural integrity and intricate designs. The layer-by-layer additive approach enables the production of these parts with reduced material waste and increased design freedom. Moreover, Meltio’s ability to work with a variety of metal alloys adds to its suitability for crafting large and complex parts tailored to specific industrial needs.

Repairs & Feature addition

Addressing issues such as corrosion, wear, or cracks, this method facilitates the incorporation of new features onto existing components, enabling upgrades or modifications without the necessity of re-manufacturing the entire part. Add layers of material to existing stock to produce a highly dense metal part, require minimal post processing and material removal.

Industries

aerospace

The Meltio system revolutionizes aerospace manufacturing by producing complex parts like blades and brackets with high precision and minimal waste. Its ability to handle diverse metal alloys aids in crafting lightweight, durable structures, advancing fuel efficiency and performance goals.

energy

This technology is employed for the repair and enhancement of turbine components, ensuring optimal performance and reducing downtime. Its adaptability to different materials allows for the production of customized components tailored to the specific requirements of diverse energy applications.

marine

The Meltio Engine enhances the marine industry by manufacturing and repairing vital ship and offshore structure components. Its laser cladding technique restores worn propellers and high-wear parts, prolonging equipment life. The technology’s precision enables corrosion-resistant coatings for parts in harsh environments.

transportation

The Meltio Engine significantly impacts the transportation sector by enabling the production of customized, lightweight components for automotive manufacturing, boosting vehicle efficiency and performance. It also supports the rail industry by repairing and maintaining essential components, increasing safety and reliability.

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