Meltio has announced the successful implementation of its metal additive manufacturing technology at ExxonMobil’s Baton Rouge refinery in Louisiana, demonstrating how advanced titanium 3D printing can transform the production of critical industrial components while significantly reducing costs and lead times.
The project focused on redesigning and manufacturing a protective anti-wicking device used to prevent oil from migrating through thermocouple wiring and contaminating instrument cabinets. While the component performs a crucial role in maintaining equipment reliability, traditional manufacturing methods presented challenges in terms of production efficiency, cost, and material utilization.
Seeking a more effective solution, engineering teams evaluated alternative materials and manufacturing approaches before selecting Titanium 64 combined with Meltio’s Laser Metal Deposition (LMD) technology on the Meltio M600 system. Historically, titanium had not been considered a practical option for such applications because of its high machining costs. However, additive manufacturing opened the possibility of producing the component more economically while maintaining the required performance standards.
The transition involved overcoming several technical challenges, including the need for an inert production environment, thermal management during printing, and optimization of deposition parameters. Engineers developed a custom fixture that enabled the simultaneous production of multiple parts, improving process efficiency and reducing oxidation risks. The component itself was redesigned specifically for additive manufacturing, incorporating advanced geometries and enhanced sealing capabilities.
Additional refinements included non-planar deposition strategies, optimized laser settings, and improved clamping systems to ensure dimensional stability throughout the manufacturing process. These measures enabled the production of durable titanium components capable of withstanding the demanding operating conditions found in refinery environments.
The results delivered substantial operational benefits. Unit manufacturing costs were reduced by 42 percent compared with conventional production methods. At the same time, lead times were compressed dramatically, falling from an estimated four to six weeks to just 58.8 hours. The improvements provided ExxonMobil with faster access to critical replacement components while reducing overall production expenses.
The successful deployment highlights the growing role of metal additive manufacturing in industries where reliability, durability, and responsiveness are essential. By combining titanium materials with advanced deposition technology, the project demonstrates how manufacturers can improve supply chain resilience, accelerate production, and unlock new design possibilities for industrial equipment.
The achievement reinforces the potential of additive manufacturing as a practical production solution for the energy sector, where minimizing downtime and ensuring equipment performance remain top priorities. Meltio develops wire-laser metal deposition technology for industrial metal additive manufacturing. The company provides metal 3D printing solutions designed to be high-performance, cost-effective, and scalable, supporting industries such as defense, energy, and manufacturing.
