In the field of industrial equipment maintenance, obsolescence is a significant risk that threatens production continuity. If specific parts are no longer supplied, companies may find themselves in a situation where they have to replace the entire facility due to the failure of a single small component.
iMet-3D, located in Lantarón, Spain, is a company specializing in solving these high-value engineering problems.
We provide integrated services ranging from design to precision post-processing using Meltio's Laser Metal Deposition (LMD) technology, and in this project, we successfully restored a core centrifugal pump in collaboration with the Bozzetto Group.
This case demonstrates that wire-to-laser additive manufacturing is a solution offering both economic and technical advantages in the field of Maintenance, Repair, and Operations (MRO).
1. Core component failure and discontinuation issues
The Bozzetto Group experienced a serious failure of its horizontal centrifugal pump.
The part where the problem occurred was the bearing support (Palier), which was no longer usable due to severe corrosion caused by prolonged exposure to a harsh atmospheric environment.
The engineering team faced the following three complex problems.
– Material degradation The existing parts were constructed of painted GG-25 cast iron, but their corrosion resistance was insufficient in actual operating environments.
– Supply Chain Gaps The pump model in question has already been discontinued, so the necessary spare parts were not available on the market. Existing manufacturers quoted a lead time of more than two months.
– Excessive replacement costs The cost of replacing the entire pump was approximately 5,000 euros, which was a very large capital expenditure to be incurred due to a single part failure.
2. Reverse engineering performed without digital drawings
iMet-3D had to create parts with complex shapes from scratch without the original CAD file.
The goal was not simple replication, but satisfying the following conditions simultaneously.
– Ensure dimensional accuracy identical to the original
– Achieves superior material performance compared to existing parts
– Realizing a price lower than the cost of replacing the entire pump
Technical Requirements:
– Precision shape restoration All reference dimensions connecting to the shaft, bearing housing, and pump casing had to be accurately reproduced.
– Material upgrade It was necessary to select a material that could print stably on the Meltio M450 and be resistant to future corrosive environments.
– Ensuring fair economic feasibility We had to maintain price competitiveness by balancing printing time and surface quality.
3. Rapid industrial repair using Meltio technology
iMet-3D designed the process based on the Meltio M450 and used Stainless Steel 316L (AISI-316L) wire as the material.
316L has excellent LMD process suitability and significantly improved corrosion resistance compared to conventional cast iron.
4. Economic Verification: LMD Effects Compared to Existing Procurement Methods
5. A New Standard for the Restoration of High-Value Industrial Assets
This project demonstrates that the Meltio M450 is not merely a prototype machine, but can be a core asset in industrial maintenance strategies.
Bozzetto Group restored the core pump without discarding the expensive equipment and secured a faster and more economical alternative through iMet-3D's technology.
This case demonstrates that LMD technology provides the following solution to the problem of discontinued parts.
– Faster production
– Lower cost
– Superior material performance
– Extending equipment lifespan
– Reduction of supply chain risk
