Additive Manufacturing Enhances Defense Readiness and Sustainment
Meltio and Fastech showcased advanced directed energy deposition solutions at the Danville event, demonstrating efficient production and repair capabilities for defense and aerospace components.
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How Additive Manufacturing Supported Defense Readiness at the Danville Event
Ready For Action: Accelerating Readiness, Sustaining the Future, held at Fastech’s facility in Danville, Virginia, brought together defense, research, and manufacturing specialists to evaluate how additive manufacturing supports readiness and sustainment across critical applications. Hosted with the support of the Institute for Advanced Learning and Research (IALR), the event positioned Danville as a growing center for advanced production and workforce development.
With participation from the Department of Defense, leading manufacturers, universities, and regional organizations, the program focused on practical strategies for improving the reliability, efficiency, and resilience of defense supply chains through advanced manufacturing technologies. The gathering also marked a significant step for Fastech, which became Meltio’s first official reference site in the United States, strengthening regional capabilities in directed energy deposition (DED).
Industry Insights on Readiness and Industrial Capability
Speakers from the defense, energy, research, and manufacturing sectors discussed how additive manufacturing is being integrated into industrial operations with the objective of strengthening readiness. Presentations highlighted the role of DED systems in shortening production cycles, supporting on-demand manufacturing, and improving the repair of critical components. Industry and academic representatives emphasized the need for closer cooperation between research institutions and manufacturers to accelerate the adoption of advanced processes across defense and high-demand industrial environments.
A panel on the adoption of wire-based DED examined technical and organizational requirements for scaling these systems. Discussions centered on workforce training, process qualification, and production workflow integration, which are essential steps for broader industrial use.
Live Demonstrations of Meltio’s Directed Energy Deposition Systems
Live demonstrations provided participants with detailed insight into how Meltio’s DED technology operates in real industrial conditions. Supported by Meltio’s engineering team, two systems were presented in real time.
The first demonstration used the Meltio M600 platform to produce a multi-material artillery component in stainless steel and marine bronze. The build showcased consistent deposition performance, controlled thermal behavior, and the ability to produce geometries required for defense sustainment activities. The part measured 161 × 161 × 606 mm and weighed 7.80 kg.
The second demonstration featured the Robot Cell Blue Laser system creating a jet engine exhaust component for aerospace use. This large-scale part, printed in stainless steel with a 0.6 mm average deposition layer at the base, reached a final weight of 11.91 kg. The process highlighted the flexibility of robotic DED for fabricating or repairing complex aerospace structures requiring high repeatability and controlled material properties.
Wireless guidance during the demonstrations allowed attendees to follow the full manufacturing sequence, from material feeding to final build completion, illustrating how DED reduces waste, shortens lead times, and supports improved supply chain resilience.
Danville’s Role in Advanced Manufacturing Development
The event underscored Danville’s growing importance as a center for industrial innovation. Regional investment in research, education, and applied manufacturing capabilities is supporting new opportunities in defense-focused production. Becoming Meltio’s first reference site in the country placed Fastech in a strategic position to support industrial partners pursuing DED solutions for sustainment, repair, and component manufacturing.
The collaboration between Fastech and Meltio demonstrated how regional expertise combined with advanced directed energy deposition technology can strengthen national manufacturing capability while providing practical pathways for industrial adoption.
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