MELTIO
Manufacturing a close impeller for a fire supression system
Original Source:
https://meltio3d.com/manufacturing-a-close-impeller-for-a-fire-supression-system/
Original Content by : MELTIO
When critical infrastructure is on the line, there’s no room for downtime. That’s exactly the case for fire suppression systems — where a single component like a closed impeller must operate non-stop to ensure the system is pressurized and ready the moment it’s needed.
For the customer, this essential part became a bottleneck: cast bronze, slow to source, and prone to wear. The solution? Reinvent it with Meltio.
Pressure never stops
Every time a fire suppression system kicks in, the impeller has to go from zero to full speed in seconds. That startup surge isn’t gentle — it forces torque through the entire system, straining every component. And that’s just the beginning.
Once running, the impeller faces constant wear from vibration, erosion, and corrosive flow. It’s not a matter of if it will degrade — just when.From cast to custom: additive manufacturing to the rescue
Traditionally, this impeller was made in cast bronze — strong, but not ideal for today’s timelines or environments. With Meltio’s Directed Energy Deposition, the customer reimagined the impeller in stainless steel 316L, boosting mechanical and corrosion resistance.
They modified the design for printability and applied Meltio’s Radial 360 toolpath strategy, with tailored supports and variable deposition. No more molds. No long delays. Just rapid, responsive manufacturing.
Key modifications included:
Material shift
To Stainless Steel 316L for greater corrosion and fatigue resistance
Geometry optimization
For printability, using a Radial 360 strategy
Custom support structures
For overhangs and variable deposition for cleaner finishes
Precision in two acts
The first print proved functional, though machining the complex geometry was a challenge — especially in high-strength steel. Surface quality under the supports wasn’t perfect, and rounded zones needed post-processing due to slight overgrowth.
The solution? Break the job into two print stages, adding a machining pass in between. With the Meltio positioning system, both phases stay perfectly aligned, allowing easier access to internal blades and tighter tolerances.
To optimize this:
Break the job
The process will be split into two printing phases
Machining step
Intermediate machining will improve blade access
Positioning system
Alignment will be preserved using Meltio’s positioning system
By shifting from traditional casting to metal additive manufacturing, the customer gained more than a part — they unlocked a better process:
Stronger part with better wear resistance
Minimized storage of spares
Rapid production without waiting on molds
Manufacture on-site and on-demand
Stronger part with better wear resistance
Minimized storage of spares
Rapid production without waiting on molds
Manufacture on-site and on-demand
System: Meltio Engine for Robot integration
lt is the perfect platform for large and complex 3D printing, repair, cladding and feature addition.
Sector: Naval
On-site, on-demand production
Material: Stainless Steel 316L
Wire feedstock proves more affordable and safer than powder-based alternatives.
Printing Time: 85h
No delays, no stockpiles: a manufacturing evolution
By shifting from traditional casting to metal additive manufacturing, the customer gained more than just a part; they unlocked a superior process. This transition eliminated inventory backlogs and long waits for replacement parts, providing access to a better material that’s ready precisely when needed.
With Meltio, maintenance transforms into momentum, ensuring fire systems remain operational, secure, and prepared for any situation.
