Two new solutions would make better use of Meltio’s wire-laser metal 3D printing technology

Laser metal deposition technology developer Meltio enhances the user experience of its wired laser metal 3D printing technology with two new solutions: a course generation software and one new laser calibration system.

In case you didn’t know, laser metal deposition is one of the most versatile processes due to its ability to perform repair or coating processes. An ideal production candidate for repairing turbine blades, as well as other high performance applications in demanding industries, the process works by generating a solder pool on the surface of the component. A metallic filler material is gradually added and melted in this bath. Beads welded to each other are created, and then form structures on existing base bodies for repairs or coatings, or form entire components.

Toolpath generator software

The CEO of Meltio, Angel LlaveroDeclare that ” metal additive manufacturing has historically been associated with complex and expensive software, limited to the use of very few people because it was very specialized – hence their desire to facilitate and shorten the learning time of AM metal.

baptized Meltio Horizonthe software solution is compatible with Meltio M450. Until now, Meltio users had to use third-party FFF slicers to prepare toolpaths for this machine.

In addition to traditional slicing parameters used in FFF software, such as layer height, line width, print speed, and support materials, Meltio Horizon software provides tailored access to the laser spinning process. of Meltio and material-specific parameters, such as laser power, double spinning and hot spinning parameters.

With Meltio Horizon software, all material-related parameters reside directly in the slicing software, allowing full control and a single profile. It also allows us to create more specialized print profiles, with the ability to directly control the laser and hot wire on a ‘per slicing function’ basis, rather than being set for the entire part.

This slicer is currently only compatible with the Meltio M450 metal 3D printer. For Meltio Engines (CNC and robot integration), the company is currently working on the development of its partnerships with the ecosystem of open software that allow the generation of 5-axis G-Codes.

The laser calibration system

The Laser Calibration System is an optional kit that would allow Meltio’s multi-laser deposition head to be calibrated precisely and effortlessly on its three metal 3D printing solutions. The system consists of a laser alignment camera which should be placed under the printhead as it allows the focus point of the lasers to be seen clearly. The camera is controlled using a handheld controller, which is also included in the kit, along with specially designed software to filter the camera image and guide the user to focus each laser on the most optimal point.

Manual laser alignment is still possible but will require a very experienced operator to achieve the consistency of the laser alignment kit.

Meltio’s multi-laser metal 3D printing technology is based on the use of six lasers pointing at a common point to melt the solder wire which is fed into the center of the deposition head. The lasers generate a high concentration of energy, called a meltpool, which melts the metallic raw material. As a result, the weld beads are stacked precisely on top of each other.

The alignment of each laser is essential so that they reach the exact point where the energy is concentrated. Misalignment of lasers leads to inefficiencies and defects in 3D printed parts. The camera makes the calibration process easy to follow.

We developed the Meltio Horizon software and laser calibration system with the goal of making it easier to use Meltio’s metal 3D printing technology for industries around the world. The launch of our new software [facilite et réduit le temps d’apprentissage, tandis que le] laser calibration system will give industrial companies a new tool to be able to work with guaranteed reliability in the creation of their metal parts », concludes Angel Llavero.

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