Meltio Helps ExxonMobil Reduce Costs by 42% and Lead Times by 90% with Titanium Wire-Laser Metal 3D Printing

Why It Matters

The cost and speed gains prove additive manufacturing can be a competitive alternative to traditional machining in high‑reliability sectors, accelerating digital‑first supply chains. It signals a shift toward lightweight, high‑performance alloys in refinery infrastructure, reducing operating expenses and downtime.

Key Takeaways

• 42% unit‑cost reduction for titanium anti‑wicking device.
• Lead time cut from 4‑6 weeks to ~60 hours.
• Meltio M600 LMD enabled batch printing of four parts simultaneously.
• Custom SS fixtures eliminated oxidation, improving surface quality.
• Titanium 64 chosen for lighter, cheaper, high‑performance parts.

Pulse Analysis

Additive manufacturing is gaining traction in the oil‑and‑gas sector, where equipment must endure extreme temperatures, vibration, and corrosive fluids. Historically, the industry relied on subtractive processes that are costly and slow, especially for high‑performance alloys like titanium. Meltio’s laser metal deposition (LMD) technology bridges that gap by offering precise, layer‑by‑layer build capabilities while maintaining the material integrity required for refinery components. By leveraging the M600 system, ExxonMobil could explore titanium‑64—a material previously deemed too expensive—without sacrificing reliability.

The project’s technical success hinged on a series of engineering innovations. Engineers redesigned the anti‑wicking device to accommodate a 75° overhang limit, eliminating the need for extensive support structures. A custom stainless‑steel fixture, printed in‑situ, created an inert chamber environment that reduced oxidation during the 1.5‑hour inertization cycle. Parameter tweaks—lower laser power and variable print speeds—addressed localized overheating and material overgrowth, while robust clamping prevented part displacement during non‑extrusion moves. These adjustments enabled batch production of four components, maximizing machine uptime and ensuring consistent microstructural properties.

Financially, the transition delivered a 42% reduction in unit cost and compressed lead times from weeks to under 60 hours, delivering immediate ROI and freeing capacity for other critical projects. The case validates LMD as a viable, cost‑effective pathway for producing complex, high‑strength parts in the energy sector. As more refineries seek to modernize legacy equipment, the demonstrated scalability and economic upside of directed‑energy deposition are likely to accelerate broader adoption, reshaping supply chains and fostering a new era of lightweight, durable infrastructure.