When it comes to critical infrastructure, there is no room for downtime. This is especially important in fire suppression systems — where a single part, such as a sealed impeller, must run continuously to keep the system pressurized and ready when needed.
For the customer, this key part became a bottleneck: a cast bronze part, hard to reach and prone to wear. The solution? Redesign with the help of Meltio technology.
The pressure never stops.
Each time the fire suppression system is activated, the impeller must go from zero to full speed in seconds. That initial surge isn't gentle — it sends torque through the entire system, stressing every part of it. And that's just the beginning.
When in operation, the impeller is exposed to constant wear due to vibration, erosion and corrosive flow. The question is not if it will wear out — but when .
From casting to custom fabrication: additive manufacturing in action
Traditionally, the impeller was made of cast bronze—tough, but not ideal for today's deadlines and conditions. With Meltio directional energy deposition technology, the customer redesigned the impeller in 316L stainless steel, improving mechanical strength and corrosion resistance.
The design is print-ready, using Meltio's Radial 360 strategy, with custom mounts and variable deposition. No mold. No long waits. Only fast and efficient production.
Key changes include:
- Material change - To stainless steel 316L for better resistance to corrosion and fatigue
- Geometry Optimization - For printing, using the Radial 360 strategy
- Custom Support Structures - To overcome overhangs and provide a cleaner finish
Precision in two acts
The first printed part was functional, but machining the complex geometry was challenging—especially with high-strength steel. The quality of the surface under the supports was not perfect and the rounded areas required additional treatment due to slight overgrowth.
The solution? Split the job into two print stages, with processing in between. With the Meltio positioning system, both stages remain perfectly aligned, allowing easier access to the internal vanes and more precise tolerances.
To optimize the process:
- Division of work - The process is divided into two printing stages
- Machining step - Intermediate machining improves blade access
- Positioning System - Alignment is maintained using the Meltio system
More than a part — a better process
By moving from traditional casting to metal additive manufacturing, the customer got more than just the part — they got an improved process:
- Harder part with better wear resistance
- Reduced need to stock spare parts
- Fast production without waiting for molds
- Production on site and as needed
Meltio solutions for 3D metal printing
Discover the potential of metal 3D printing with Meltio. Your journey starts here.
- System: Meltio Engine for robotic integration
- Sector: Maritime
- Material: Stainless steel 316L
- Printing time: 85 hours
No delays, no inventory: the evolution of manufacturing
By switching from traditional casting to metal additive manufacturing, the customer got more than a part — they got a superior process. This transition eliminated inventory hold-ups and long waits for replacement parts, allowing access to better material that is ready exactly when it is needed.
With Meltio, maintenance turns into momentum, ensuring fire suppression systems remain operational, safe and ready for any situation.
Source: https://meltio3d.com/manufacturing-a-close-impeller-for-a-fire-suppression-system/