The MELD Manufacturing 3PO system is an advanced hybrid manufacturing platform that redefines how, where, and when large, forged parts are produced, repaired and sustained. The 3PO integrates MELD Manufacturing’s patented Additive Friction Stir Deposition (AFSD) forging process with proven precision subtractive machining processes into a single system; delivering a novel solution to the traditional manufacturer of critical in-demand forgings for the aerospace, space, and defense industries. The combination of “additive manufacturing” with subtractive manufacturing is commonly referred to as “Hybrid Manufacturing”. MELD’s 3PO is the first product to enable hybrid capability for forged products.

At the core of this revolutionary 3PO platform is the MELD process. MELD is a novel solid-state metal deposition process that combines the physics of forging with the flexibility of 3D printing. Rather than the use of lasers or electron beams to melt the metal (as is the case in almost all other metal 3D printing technologies), MELD uses a combination of friction (through rotation of the nozzle) and force to deposit the metal at about 60% of its melting point. This no-melt approach offers the user a safer, greener, and cost effective approach when compared to alternative, more traditional solutions.

The 3PO's hybrid architecture also eliminates the need for secondary machining processes. 3PO offers both 3 and 5 axis precision machining heads in addition to the MELD deposition head. This powerful combination allows for large scale part production up to 381 cubic feet, saving time, cost, and manufacturing floor space. The 3PO system is designed to support high volume production of large-scale, forged components such as aircraft frames, ground vehicle hulls, and structural components of spacecraft.

The MELD 3PO offers a solution to a fundamental challenge facing the aerospace and defense industries rising demands for forgings. The established process to ordering and receiving a forging requires months of waiting and expensive tooling to be manufactured. The MELD 3PO machine can help take direct control of this supply chain challenge. What was a global puzzle of foundries, forging houses, and machine shops can now be accomplished within the footprint of a single 3PO machine (26.5 FT x 36 FT). With the MELD process, the forging is hours away and the cost of forge tooling is eliminated. If the time spent waiting on a forging is not acceptable, or the cost of tooling is a non-starter, then the MELD 3PO is a great solution.

The MELD 3PO is not just a machine, it is a platform for innovation, resilience and readiness, empowering defense and aerospace companies to produce critical components faster, and safer while maintaining the same properties required to meet production and safety standards. By merging additive and subtractive capabilities into one system, the MELD 3PO is creating the future of manufacturing, one layer at a time.