At
Formnext 2026 in Frankfurt
Meltio is showcasing a range of wire-laser metal 3D-printed components at stand 12.0 C119, highlighting how its directed energy deposition (DED) technology is being used in production and repair applications across sectors including automotive, defence, mining, oil and gas, shipbuilding and aerospace. The company is also conducting live printing demonstrations throughout the exhibition.
Among the applications on display is a high-performance exhaust header developed by
DMZ for the automotive sector. Produced using Meltio's metal additive manufacturing technology, the stainless-steel component was designed to withstand high temperatures and mechanical stresses while incorporating complex geometries that optimise exhaust gas flow. The redesign reduced assembly time from eight hours to just one and was fitted to an Abarth 595, which subsequently completed around 10,000km of road use, including 600km of track driving, with the component reportedly remaining in its original condition.
DMZ has also employed the technology to reinforce steel vehicle wheels by adding material in strategically selected areas to increase rigidity. The project aimed to improve wheel stiffness while retaining the weight advantages associated with steel wheels. According to the company, the optimised design achieved the same natural frequency as an alloy wheel while maintaining a lower overall weight.
In another example, additive manufacturing was used to overcome the challenge of replacing an obsolete industrial component. Following the failure of a critical centrifugal pump,
IMET3D produced a replacement part using Meltio's wire-laser metal 3D-printing process. Rather than replacing the entire system, the damaged component was redesigned and manufactured in 316L stainless steel, providing improved corrosion resistance compared with the original cast-iron version. The project demonstrates how metal additive manufacturing can help industrial users restore equipment quickly, locally and cost-effectively when replacement parts are no longer available.
Formnext runs from November 17-20 in Frankfurt.