Meltio’s hybrid-metal 3D printing technology is setting new standards in naval engineering. During the RIMPAC 2024 exercise, the system enabled the crew of the USS Somerset to solve a critical technical problem, confirming the disruptive potential of advanced manufacturing technology.
Revolutionising the defence industry
The adoption of advanced manufacturing technologies is changing the face of many industries, including the naval defence sector. At the heart of this transformation is Meltio technology, which integrates additive and subtractive manufacturing in a single system. During RIMPAC 2024, the largest international naval exercise, the technology played a key role aboard the USS Somerset, the US Navy’s San Antonio-class landing ship.
Snowbird Technologies, Meltio’s US commercial partner, deployed the SAMM Tech system with Meltio’s 3D printing head, enabling the ship’s crew to quickly resolve a critical technical issue.
The challenge: failure of a critical system
Maritime operations are inherently complex and often take place away from logistics facilities. Equipment failure in such conditions can have serious consequences, especially when key systems are affected. This was the case at the start of RIMPAC 2024, which involved 29 nations, 40 ships and more than 25,000 personnel.
On board the USS Somerset, a reverse osmosis pump, essential for producing clean drinking water for the crew, failed. The lack of a working system could have shortened the ship’s mission and jeopardised the exercise.
Photo Credit: Meltio
The Solution
A traditional replacement for this part would have required weeks or months of waiting for a replacement to be delivered. However, thanks to SAMM Tech’s technology and Meltio’s 3D printing head, the crew of the USS Somerset was able to produce the missing part within hours. This allowed them to quickly restore pump operation and ensure the ship’s operational readiness.
“We didn’t expect to be able to contribute to the ship’s readiness so quickly, especially with a system as vital as the reverse osmosis pump,” said Charles Wallace, mechanical engineer at the Naval Postgraduate School.
Breakthrough capabilities of Meltio’s hybrid technology
Meltio’s hybrid-metal 3D printing system allows components to be digitised and converted into a computer design that is sent to a machine. Parts can be produced from this design, making them easier to reproduce in the future. This capability significantly improves the efficiency of production and reproduction of critical components, particularly in remote or challenging environments.
The SAMM Tech system can reduce the delivery time of critical parts from days to hours. In addition, components produced using this technology do not require post-processing or heat treatment, making them ideal for military applications requiring rapid deployment of durable metal components.
Benefits of Meltio’s technology
Meltio’s 3D printing technology brings a number of benefits to the maritime sector:
- Efficient material management: Eliminates the need to store large quantities of materials, such as metal blocks or bars, by using metal wire
- Greater autonomy: On-site production of parts reduces reliance on external suppliers and reduces delays
- Savings: Repairing damaged parts is less expensive than producing new ones
- Customisation: Technology enables the creation of customised parts to meet specific mission requirements
- Increased mission resilience: On-demand manufacturing allows ships to operate in remote or harsh environments without returning to port
- Green solution: Minimises material waste and CO2 emissions associated with logistics
Summary
Trials of Meltio’s technology aboard the USS Somerset have confirmed its potential to revolutionise military supply chains. Reducing delivery times for critical parts from days to hours provides unparalleled flexibility and resilience, even in the most demanding environments.
“If crews had to rely on traditional parts replacement, the wait could be weeks or months. With this technology, the new component is ready for installation before a traditional order would have been filled”, said Staff Sergeant Jordan Blake of the Marine Innovation Unit.
