Meltio consolidates during 2025 its leading industrial metal AM case studies and its increasing participation in international events by regularly exhibiting at major trade shows across different industries, such as MilAm, Rapid TCT, EMO Hannover and Formnext during this year for manufacturing technology

Linares (Spain), December 15th 2025 .- Meltio, a multinational leader in wire-laser metal additive manufacturing, has concluded a decisive 2025 exhibition circuit, confirming that Directed Energy Deposition (DED) technology has graduated from experimental labs to active supply chains in multiple worldwide industries. Through strategic demonstrations at four major global events during this year —MilAM, Rapid+TCT, EMO Hannover, and Formnext— the company provided data-driven validation that its solutions are decoupling manufacturers from fragile global logistics.

The current year has been marked by the opening of Meltio's first international reference site in Danville, Virginia (United States), and the operational deployment of systems by defense bodies, including the Republic of Korea Marine Corps and the U.S. Navy, and other defense real use cases.

Trade shows specializing exclusively in additive manufacturing are not the only relevant venues for demonstrating an industrial metal 3D printing system's efficiency. To demonstrate and convince potential manufacturer customers, who need to trust AM technology to create and repair metal parts in their production cycles and machine shops, of the reliability and productivity of metal AM compared to traditional manufacturing methods such as boilermaking or casting, it is essential to attend other major industrial manufacturing trade shows interested in adopting AM. That's why Meltio has participated in multiple AM and other international events in 2025.

Logistics in contested environments
At MilAM and Rapid+TCT, the focus was on operational readiness. The U.S. Department of Defense and other global forces are actively seeking to integrate additive manufacturing (AM) to resolve mission-critical supply challenges.
? Operational validation: The highlight of the defense circuit was the operational validation of the Meltio Robot Cell. A case study was presented, where a critical reverse osmosis pump was restored in just 34 hours aboard a ship, significantly outpacing traditional procurement timelines.
? Lightweighting tactical gear: In a collaboration with AM Solutions for the South Korean defense sector, Meltio's technology was used to redesign ice cleats for the K2 Black Panther main battle tank. The original 10.74 kg pads created physical strain for soldiers; the AM-optimized honeycomb structure reduced the weight to 4.26 kg, a 60% reduction, while maintaining mechanical integrity.
? Hybrid Manufacturing: Partnering with Phillips Corporation, Meltio showcased the first integration of the Meltio Engine Blue into a Haas CNC machine. Meltio Hybrid manufacturing CNC integration is allowing defense manufacturers to produce complex metal parts with enhanced precision, reduced lead times, and less material waste, key factors in deployment and sustainment scenarios

"While stainless steel additive manufacturing onboard naval ships is new, it represents an advancement in providing sailors with industrial-level manufacturing capabilities to print individual parts for systems that previously have not been readily available."

Industrial efficiency: Automotive, Tooling, Oil and Gas
Shifting focus to high-volume efficiency at EMO Hannover and Formnext, Meltio addressed the economic limits of milling and casting. The narrative here was defined by Return on Investment (ROI) and cycle time reduction.
? Cost and weight reduction: The Hirudi Stub Axle case study served as a definitive argument for hybrid manufacturing. By switching to Meltio's Wire-Laser Metal Deposition (W-LMD) process, the manufacturer achieved a 62.5% weight reduction and a 35.7% cost reduction compared to traditional forging cycles.
? Speed: The stub axle was produced in just over 21 hours, cutting lead times by 33%.
? Adoption: This data validates the technology for functional engine components and tooling, supporting integration by automotive giants such as Iveco.

Securing supply chains through on-site autonomy
The vulnerability of global supply chains was a central theme at the opening of Meltio's international reference site in Danville, Virginia, where the focus extended to the Oil & Gas sector. For energy operators working in remote or offshore environments, the delay of a single critical component can cost millions in downtime. Meltio demonstrated how its technology effectively decouples these companies from fragile logistics networks by enabling "Industrial Autonomy", the ability to print or repair parts on demand, right where they are needed.

? Remote repair capabilities: Much like the validated use cases in naval defense, Meltio showcased solutions capable of processing corrosion-resistant superalloys (such as Inconel 718 and Stainless Steel) essential for the harsh conditions of the energy sector.
? High-performance applications: At Formnext, specific application examples for Oil & Gas were presented, including complex geometries like dual combustion chambers with integrated cooling channels. These demonstrations proved that W-LMD can match the material density and mechanical properties required for safety-critical energy infrastructure while reducing lead times from months to days.

Blue Laser integration
Driving these applications is the rollout of the Meltio Engine Blue. Featured prominently at Formnext, this system utilizes a 1 kW Blue Laser, factory-calibrated to process reflective materials like copper and aluminum with higher absorption rates than infrared lasers.
? Efficiency metrics: The system delivers a 30% reduction in energy consumption and deposition rates up to 3.5x faster than previous generations.
? Material versatility: At the new Danville reference site, Meltio displayed multi-material capabilities, including an artillery shell and a naval propeller shaft bracket printed in Marine Bronze and stainless steel.

Expanding the global footprint
Beyond the technology, 2025 marked a geographical expansion. Meltio opened its first international reference site in Danville, Virginia, in partnership with Fastech. This facility serves as a hub for the North American defense, oil and gas, and naval sectors, allowing customers to witness the hardware, including the Meltio M600 and Robot Cell, producing real industrial parts.
"Metal Additive Manufacturing is growing in demand among the global industrial sector," said Lukas Hoppe, Head of R&D at Meltio. "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 industrial global Directed Energy Deposition (DED) metal wire 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 1 suppliers and Defense forces decouple from fragile global supply chains.

More real applications
Meltio has increased during 2025 the number of success stories and industrial applications that Meltio has experienced in the automotive, defense, aerospace, mining, oil and gas.
"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 wire-laser metal 3D printing solutions into the manufacturing floor and the machine shops to lower costs, increase efficiency and overcome challenges such as supply chain stability.", explains Lukas Hoppe, Head of R&D at Meltio.

Please, see here all the Meltio real use cases for industries:
https://meltio3d.com/resources/

About Meltio
Meltio takes metal additive manufacturing to the next level by developing high-performance, affordable, and easy-to-use metal 3D printing solutions using wire-laser metal deposition (LMD) technology. The company's mission is to pioneer the development of reliable metal 3D printing systems that function as standard industrial tools. Meltio takes metal additive manufacturing to the next level by developing and manufacturing high-performance, affordable and easy-to-use metal 3D printing solutions using wire laser metal deposition (LMD) technology - a business segment within DED energy direct material deposition technology. Meltio's offerings include the Meltio M600, the new Meltio Engine Blue and the second generation of Blue Laser solutions: the Meltio Engine Blue Integration kit for CNC machines, which turns virtually any computerized machine and CNC milling machine into a powerful hybrid manufacturing center, and the new Meltio Engine Blue integration kit for robotic arms. And the Meltio Robot Cell, an affordable turnkey containerized solution for Meltio Engine Robot Integration. www.meltio3d.com