Meltio, a world leader in wire-laser metal additive manufacturing (AM), has concluded a decisive 2025 exhibition circuit, confirming that Directed Energy Deposition (DED) technology has moved beyond experimental labs and into active supply chains across multiple global industries.
Through strategic demonstrations at four major international events last year —
MilAM,
Rapid+TCT,
EMO Hannover and
Formnext — the company provided data-driven validation that its solutions are helping manufacturers decouple from fragile global logistics.
2025 also saw the opening of Meltio’s first international reference site in Danville, Virginia, and the operational deployment of systems by defence bodies including the Republic of Korea Marine Corps and the US Navy. The company says that these real-world applications underscore the technology’s readiness for mission-critical environments. At
MilAM and
Rapid+TCT, the focus was on operational readiness, with the US Department of Defence and other global forces actively seeking to integrate AM to resolve supply challenges.
One highlight was the operational validation of the Meltio Robot Cell, where a critical reverse osmosis pump was restored in just 34hr aboard a ship, far outpacing traditional procurement timelines. In another case, Meltio’s technology was used to redesign ice cleats for the K2 Black Panther main battle tank, reducing weight by 60% while maintaining mechanical integrity. Partnering with
Phillips Corporation, Meltio also showcased the first integration of the Meltio Engine Blue into a Haas CNC machine, enabling hybrid manufacturing that combines additive and subtractive processes for complex metal parts with enhanced precision and reduced lead times.
At
EMO Hannover and
Formnext, the focus was on industrial efficiency for sectors such as automotive, tooling and oil and gas. A case study on a Hirudi stub axle demonstrated a 62.5% weight decrease and a 35.7% cost reduction compared to traditional forging, with production completed in just over 21hr — cutting lead times by 33%. These results validate the technology for functional engine components and tooling, supporting adoption by major automotive manufacturers such as
Iveco.
Industrial AutonomyThe vulnerability of global supply chains was a central theme at the opening of Meltio’s Danville reference site, which showcased solutions for remote and offshore environments where delays in critical components can cost millions in downtime. Meltio demonstrated how its technology enables “Industrial Autonomy” by allowing companies to print or repair parts on demand, including corrosion-resistant superalloys essential for harsh conditions.
At
Formnext, Meltio also presented complex geometries for oil and gas applications, such as dual combustion chambers with integrated cooling channels, proving that wire-laser metal deposition (WLMD) can meet the material density and mechanical properties required for safety-critical infrastructure while reducing lead times from months to days.
Driving these applications is the roll-out of the Meltio Engine Blue, which uses a 1.4kW Blue Laser to process reflective materials like copper and aluminum with higher absorption rates than infrared lasers. The system delivers a 30% reduction in energy consumption and deposition rates up to 3.5-times faster than previous generations, while offering multi-material capabilities demonstrated through components such as an artillery shell and a naval propeller shaft bracket printed in marine bronze and stainless steel.
Beyond technology, 2025 marked a significant geographical expansion for Meltio with the opening of its Danville facility in partnership with
Fastech. This site serves as a hub for North American defence, oil and gas and naval sectors, allowing customers to witness Meltio hardware producing real industrial parts.
Meltio’s head of R&D Lukas Hoppe said: “Metal AM is growing in demand among the global industrial sector. It solves the needs of these customers to obtain parts and repair them effectively and reliably, and guarantees them greater autonomy since Meltio’s equipment is installed directly in their workshops.”
The company’s presence at these events highlighted a single, unified narrative: Industrial Autonomy. By enabling the production of near-series components on demand, Meltio is helping Tier One suppliers and defence forces decouple from fragile global supply chains.
Mr Hoppe concluded: “The need for AM has never been greater and we understand those industrial customer needs and we are clear to demonstrate to them the clear advantages of integrating Meltio WLMD solutions into the manufacturing floor and the machine shops to lower costs, increase efficiency and overcome challenges such as supply chain stability.”