Sponsored By Oxley Developments
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18 Sep 25. Argonne captures 3D Printing Metal Microstructures. In one form of additive manufacturing, complex metal parts are built one ultra-thin layer at a time — similar to frosting a cake, but with far greater precision and intricacy. This technique allows for the printing of 3D parts that are difficult or impossible to make using traditional methods. It also offers a path forward to ease supply chain disruptions and modernize domestic manufacturing.
Additive manufacturing is already used to produce metal components for critical sectors like aerospace, healthcare and defense. But a major challenge remains: achieving consistent quality and repeatability from part to part.
Now, in a major scientific advance, researchers at the U.S. Department of Energy’s (DOE) Argonne National Laboratory, DOE’s Oak Ridge National Laboratory and universities have observed how the microstructure of metals changes in real-time during 3D printing. This breakthrough was made possible by Argonne’s Advanced Photon Source (APS), a DOE Office of Science user facility.
The team investigated an additive manufacturing technique in which a laser rapidly melts a thin metal wire. As the metal melts, it is deposited on the previous layer after the first, followed almost instantly by cooling and solidification. This process is repeated layer by layer to create intricate components. Previously, scientists could only analyze the microstructures of these components after the printing process was finished.
Using the APS, the team conducted 3D printing of 316L stainless steel, a commonly used structural alloy. They tracked the printing process with real-time X-ray diffraction, directly measuring how and when dislocations form and spread.
The data revealed that dislocations form early, just as the metal changes from liquid to solid. It was previously thought that they form later as stresses build up during cooling and solidification. A key factor was a specific reaction in which two solid phases form at the same time from the liquid, creating a high density of dislocations.
This deeper understanding could help engineers improve the strength and reliability of 3D-printed parts. By adjusting printing variables, developers would be able to precisely control the formation of dislocations at the microscopic level. By this means, they could take full advantage of the dislocations’ beneficial attributes while minimizing the detrimental ones.
The insights gained could also spur the development of new alloys. Adjusting the chemical makeup of stainless steels — for example, by tweaking the ratios of chromium or nickel, or by adding elements like aluminum — can influence how dislocations form and how stress is distributed. (Source: BUSINESS WIRE)
18 Sep 25. German Army expand digital C2 to all levels – with SitaWare Edge. As part of their digital transformation, the German Armed Forces have signed a contract with Systematic to equip their dismounted personnel with the world-leading command and control software SitaWare Edge. As part of their digital transformation, the German Armed Forces have signed a contract with Systematic to equip their dismounted personnel with the world-leading command and control software SitaWare Edge. The acquisition of the enterprise license marks another important milestone within the Bundeswehr’s Mission Enabling Service (MESBw) – the unified software ecosystem designed to support command at all levels. SitaWare Edge will be deployed in the ‘Portable’ variant of the MESBw, complementing ‘Command Post’ (SitaWare Headquarters) and ‘Mounted’ (SitaWare Frontline); tactical areas in which the software has already been successfully implemented and operationally proven. Together, these capabilities enable seamless digital command-and-control – from stationary or deployable command posts, through vehicle-based systems, to dismounted forces, providing everyone with a full situational awareness of planning and operations. The acquisition also includes the associated Software Development Kits (SDKs), providing the foundation for an open C4ISR ecosystem – which allows for 3rd party integrations, to meet the individual requirements of the Bundeswehr.
We are proud that the Bundeswehr continues to rely on Systematic as a trusted partner in their ongoing digital transformation. The introduction of SitaWare Edge is another important step, delivering our software capabilities to the very frontline. – Sven Trusch, Managing Director of Systematic’s German subsidiary
Command and Control for the tactical edge
SitaWare Edge brings several decisive advantages to the tactical level. It provides commanders on the ground with comprehensive situational awareness and intuitive mission management tools, enabling them to stay focused on the mission rather than the system. By relying on the proven SitaWare tactical communications protocols, it ensures that vital battlefield information is shared seamlessly under all conditions, improving tempo and enhancing safety.And with advanced planning and mapping capabilities available, SitaWare Edge helps shorten the decision cycle – giving commanders the ability to act faster and outmanoeuvre the adversary.
The SitaWare Suite
SitaWare is the operationally proven C4ISR solution that delivers superior tactical communication, unmatched interoperability, seamless collaborative planning and comprehensive situational awareness across the battlespace.
As an advanced C4ISR application, it allows all levels of command and all domains to exchange vital information and extensive plans within own, coalition, and joint battle networks.
SitaWare is used by more than 50 countries worldwide and is a trusted force multiplier. Its proven ability unites armed services and ensures efficient communications and decision-making from the command right to the tactical edge.
10 Sep 25. Flare Bright introduces Extera at DSEI. Flare Bright is exhibiting within the ADS Pavilion at DSEI 2025, where they will be showcasing their innovative suite of GPS-free navigation technology and launching their new flight termination safety system, Extera. Extera is designed to assure containment during critical drone operations and accelerate the testing and evaluation of novel drone systems for both the defence and civil sectors. Flare Bright’s navigation solutions are on the market now and being used and evaluated by end-users and field personnel. Extera, also now available, is currently being used in real conditions to accelerate defence testing and evaluation programmes, with significant buy-in from the civil sector. Founded in 2015 by Dr Kelvin Hamilton FRAeS and Dr Conrad Rider, Flare Bright has been at the forefront of developing robust and resilient technologies for a variety of mission-critical applications. The company’s core technology, built on a machine learning digital twin foundation, enhances navigation in environments where GPS and other radio frequency signals are denied.
At DSEI 2025, Flare Bright featured a physical airside unit from its Flight Termination System (FTS) and a Tactera GPS-free terrain navigation unit which will allow visitors to see firsthand the incredibly small form factor of the company’s terrain navigation solution.
Navigation Products on display and key talking points included:
- Tactera: a high-accuracy, strike-grade absolute positioning system. Built with commercially available off-the-shelf components and advanced software, it offers exceptional navigational accuracy, day or night. Tactera uses readily available commercial terrain elevation maps,and is well suited for low and fast cruise missile applications
- Intera (Software-Enhanced INS): Experts will be available to discuss Intera, Flare Bright’s software-enhanced inertial navigation system. This technology provides long-range, GPS-free navigation, even over featureless environments like open water, offering a powerful solution for extended missions
Flight Termination System (FTS): The airside unit of Flare Bright’s brand-new FTS, Extera, will be on display. This ultra-reliable, scalable and independent hardware and software system allows for the command termination of a drone’s flight, a critical capability for safe testing in constrained airspace and for mission assurance.
Flarebright have committed to servicing industry demand by opening a manufacturing and test facility to take full advantage of the UK’s skillbase and manufacturing heritage, creating a wide range of skilled and semi-skilled jobs in the heart of the country.
Kelvin Hamilton, CEO of Flare Bright, commented: “DSEI 2025 is a crucial event in the global defence calendar. We are proud to be part of the ADS Pavilion, where we look forward to meeting with delegations and potential industrial partners. Our vision is to become the world’s most trusted supplier of software-based capability enhancements for uncrewed vehicles, and DSEI provides an invaluable platform to advance this mission.”
11 Sep 25. Flarebright signed an Memorandum of Understanding (MOU) with QinetiQ’s DroneWorks which is part of QinetiQ’s commitment to transform the delivery of mission-critical T&E capabilities to enhance operational readiness of the UK and allied nations. QinetiQ and the Ministry of Defence (MoD) have agreed changes to the Long Term Partnering Agreement (LTPA) that will make it easier and cheaper for small and medium sized enterprises (SMEs) to use test and evaluation (T&E) capabilities across the UK.
SMEs, who are key to accelerating research, development and innovation in defence will now pay significantly less to access technical expertise and test ranges.
The changes form part of QinetiQ’s commitment to transform the delivery of mission-critical T&E capabilities to enhance operational readiness of the UK and allied nations. The new T&E Innovation Gateway will reduce the barriers to access that have made it difficult for SMEs to take advantage of the UK’s world-leading T&E capabilities delivered by QinetiQ on behalf of the MoD.
In an ever-evolving threat landscape, the rapid acquisition of technology is vital to ensure the UK and allied nations have operational advantage to achieve mission success. SMEs and non-traditional defence companies have a critical role to play in helping bring disruptive technologies from concept to reality, at pace.
The cost reductions, together with QinetiQ’s investment in the new T&E Innovation Gateway, will encourage more innovators to come forward with solutions that can be put rapidly through their paces so that relevant capability can be accelerated to support frontline operations.
QinetiQ has built a team that is dedicated to supporting SMEs, helping them to access test and evaluation expertise, identify suitable ranges and facilities and secure the right approvals to facilitate rapid solution development and testing in realistic operational environments.
Luke Pollard, Minister for Defence Readiness and Industry, said: “This Government wants more SMEs to benefit from the historic uplift in defence spending. To make defence an engine for growth, we need more SMEs to access the facilities to get their technology to the frontline. This investment is a big step forward and demonstrates our commitment to SMEs who play a vital role, not just in defence, but also in supporting the wider UK economy.”
Steve Wadey, Group CEO, QinetiQ, said: “More than ever, SMEs are key to accelerating the pace of innovation across defence and we want to help them bring their technologies to the frontline. Our investment in the T&E Innovation Gateway will not only provide easier access to our expertise and the facilities we operate, it will reduce costs, enabling more companies to develop and test their products in realistic operational scenarios, boosting defence innovation and economic growth in the UK.”
Recently, QinetiQ has been supporting SMEs with the development, rapid proto-typing and evaluation of new Uncrewed Air Systems (UAS) and Counter UAS (C-UAS) technologies through the company’s DroneWorks test capability.
More information about the T&E Innovation Gateway and how it can support SMEs is available at: https://www.t3e.uk/en/services/test-and-evaluation-innovation-gateway
16 Sep 25. BUOYANCY AEROSPACE announced the launch of its Thin-Film Sulphuric Acid Anodising (TFSAA) treatment line (MIL-A-8625 Type IIB), a production-ready capability engineered for aerospace and defence manufacturing. The line is fully automated with a custom-developed PLC that provides deterministic, high-resolution control at the tank level. The system has been validated through 100+ fault-injection scenarios to deliver fast, predictable responses. Since entering commercial production, BUOYANCY AEROSPACE has reported no out-of-spec process-control events to date. Unlike conventional lines relying on single-tier shut-offs, the installation combines power isolation (circuit breakers), multi-sensor detection (smoke and heat), and automatic suppression, designed in accordance with RISCAuthority RC45 guidance for electroplating fire safety; integrated advanced monitoring supports operator situational awareness.
“This investment de-risks customer programmes by embedding resilience and upgrade paths directly into our processes for sovereign defence manufacturing,” said Dr. Deepak Asokan, UK Head of Operations.
- Why it matters
End-to-End Solution: Integrated with Non-Destructive Testing (e.g., UT, PT, MT, ET and radiography as specified) and a modern paint facility qualified for aerospace coatings, including fracture-critical components where specified.
- Future-Ready Capability: Cr(VI)-free chemistries including TCS/PACS for conversion and post-seal, together with digital traceability via the company’s MES/QMS, enable rapid scaling and upgrades with minimal disruption.
“This is a safety-integrated, scalable treatment capability for critical aerospace components,” said Daniel Hutta, UK Head of Quality, Compliance, Health & Safety at BUOYANCY AEROSPACE, who led the cross-functional programme.
17 Sep 25. Steadicopter, a leader in the Rotary Unmanned Aerial Systems (RUAS) industry, is proud to announce a new operational capability developed in collaboration with ParaZero: the integration of the DropAir precision airdrop system into Steadicopter’s Black Eagle 50E all-electric unmanned helicopter. The DropAir module transforms the Black Eagle 50E into a highly accurate and autonomous airborne delivery platform. Equipped with dual-mode parachute deployment and advanced drop algorithms, the system enables precise mid-air release of mission-critical payloads—including medical supplies, ammunition, or spare parts—with minimal drift, even in harsh conditions or GPS-denied environments. Combined with the Black Eagle 50E’s VTOL capabilities, long endurance, and minimal logistic footprint, this integration supports rapid, flexible resupply across remote or contested areas. It is ideal for both tactical and humanitarian missions.
“This collaboration with ParaZero brings a new level of agility and precision to aerial logistics,” said Noam Lidor, CEO at Steadicopter. “Together, we are enabling forces to operate smarter and faster-delivering supplies exactly where and when they’re needed, with no compromise on accuracy or safety.”
“Our shared vision to enhance unmanned aerial capabilities is reflected in this integration,” added Ariel Alon, CEO of ParaZero. “With DropAir onboard, the Black Eagle 50E becomes a powerful tool for precision aerial delivery in the most demanding environments.”
About Black Eagle 50E
The Black Eagle 50E is a mature, operational, high-performance, all-electric propulsion , providing superior-high-quality real-time intelligence, with high mission versatility and nearly zero logistic footprint . It supports multi-mission operations with advanced sensors and payload integration.
About Steadicopter
Steadicopter Ltd. is a leading developer of rotary tactical unmanned aerial systems for military, homeland security, and civilian missions. Its vertical take-off and landing UAVs are known for endurance, adaptability, and advanced mission sensor suites. The company is ISO 9001:2015 certified for development, manufacturing, and marketing.
For more information, visit: https://steadicopter.com/
16 Sep 25. Getac Technology Corporation (Getac), a leading provider of rugged computing and mobile video solutions and a manufacturer with advanced in-house capabilities, today announced the launch of its next generation UX10 and UX10-IP fully rugged tablets. The UX10 is aimed at professionals in the defence, manufacturing, utilities, public safety, and transportation & logistics industries, who need highly versatile devices they can rely on in a wide range of challenging operational scenarios. The UX10-IP is purpose-built for emergency healthcare and public safety professionals, featuring a unique sealed design that enables the device to be repeatedly cleaned and disinfected.
Accelerated performance on the latest Copilot+ PCs
The next gen UX10 and UX10-IP are the latest Getac devices to meet Microsoft’s stringent Copilot+ PC criteria2, joining the recently launched B360 Plus laptop and F120 tablet in its rapidly growing portfolio.
Both new devices are powered by an Intel® CoreTM Ultra 200V Series Processor and groundbreaking Intel® AI Boost NPU (Neural Processor Unit) with up to 48 TOPS (Trillion Operations Per Second), which can accelerate AI-driven tasks, enhance real-time analytics, and empower users to overcome difficult challenges. Other Copilot+ PC key features include up to 32GB LPDDR5X memory, up to 2TB PCIe NVMe SSD storage, and Windows Hello face authentication; (an optional fingerprint reader is also available).
Elsewhere, the next generation UX10 and UX10-IP include a range of further upgrades over the previous generation. These include improved power efficiency for longer runtime between charges, a slimmer and lighter bridge battery (optional) for enhanced overall mobility, Wi-Fi 7 for seamless connectivity, and two Thunderbolt TM 4 Type-C ports for ultra-high-speed data transfer.
Fully rugged reliability in a compact and lightweight form factor
Like all of Getac’s solutions, the next gen UX10 and UX10-IP are built rugged from the ground up for excellent reliability and usability in the field. A 10.1-inch, 1,000 nits display offers enhanced durability and superb readability, even in direct sunlight, while the touchscreen can be operated with gloves on and in the rain. The devices are also MIL-STD-810H and IP66 certified, vibration and 6ft drop resistant, and boast an operating temperature range of -29°C to 63°C / -20°F to 145°F. Despite all this, they weigh just 1.15kg/2.53lbs, making them ideally suited to all-day use in the field.
UX10 – Suited to a diverse range of critical industry applications
The combination of power, versatility and portability makes the next gen UX10 ideally suited to a wide range of critical applications across the defence, manufacturing, utilities, public safety, and transportation & logistics industries.
- For defence professionals, its compact size, light weight and advanced security features make it ideally suited to drone control and intelligence gathering activities.
- For manufacturing operators, the built-in NPU brings powerful, on-device intelligence to the factory floor, enabling the use of both generative and discriminative AI models for efficient predictive maintenance. This is complemented by extensive connectivity and video streaming, which support real-time process monitoring.
- For utilities field engineers, the UX10’s wide temperature operating range, AI-powered processing capabilities and sunlight readable screen make data intensive mapping activities and processing/analysing images for anomalies fast and efficient.
- For public safety professionals, its on-device NPU and rugged design make the UX10 ideally suited to AI-driven applications such as real-time transcription, video analysis, and evidence categorization, enabling faster, more accurate response in critical situations.
- For transportation & logistics professionals, the UX10 excels in large-scale warehousing environments where workers and forklift drivers move between cold storage and outdoor areas exposed to the elements. The device can also be securely mounted in vehicle cabins for real-time navigation, delivery processing, and inventory management, helping drivers stay productive and on schedule.
UX10-IP – Designed for infection prevention
The next gen UX10-IP is purpose-built to help emergency healthcare responders and providers prevent the spread of infection during busy shifts, featuring an innovative sealed button design that enables it to be quickly cleaned and disinfected between uses. An easy-to-clean rubber hand strap specifically designed for emergency services use is also available if required.
“The next gen UX10 and UX10-IP give enterprises a uniquely versatile platform to bring advanced AI into the field,” says Amanda Ward, EMEA Senior Director of Technology & Services, Getac Technology Corporation. “Their compact form factor, rugged reliability, and deep customization options make them ideal for running generative AI and machine learning proof of concepts across industries, from predictive maintenance in manufacturing to real-time situational awareness in public safety. By combining Copilot+ PC capabilities with extensive extension and configuration possibilities, the UX10 series empowers organizations to safely innovate, adapt, and scale AI applications in challenging environments.”
Both UX10 and UX10-IP will be available in October.
1The UX10 was named 2023 Best Rugged Tablet by Techradar.
2Microsoft’s Copilot+ PC minimum requirements include an NPU capable of 40+ TOPS, at least 16GB of memory, 256GB of storage and one or more biometric security feature.
For more information, please visit www.getac.com
15 Sep 25. USAF receives second B-21 Raider flight test aircraft. The second aircraft will boost USAF testing capabilities, shifting focus from flight performance to mission systems and weapon integration. The US Department of the Air Force has taken delivery of its second B-21 Raider flight test aircraft at Edwards Air Force Base in California.
The arrival of the second aircraft is expected to enhance the US Air Force’s (USAF) testing capabilities. This will allow for a transition from initial flight performance assessments to critical evaluations of mission systems and weapon integration.
With two test aircraft at the base, USAF’s maintainers will gain essential experience in managing simultaneous sustainment operations.
This setup allows for testing the efficiency of maintenance tools, technical data, and logistical processes necessary for future operational squadrons.
USAF Secretary Troy Meink said: “With the arrival of the second B-21 Raider, our flight test campaign gains substantial momentum. We can now expedite critical evaluations of mission systems and weapons capabilities, directly supporting the strategic deterrence and combat effectiveness envisioned for this aircraft.”
Alongside this expanded flight-testing initiative, the USAF intends to commence major military construction projects at all three designated B-21 main operating bases during the fiscal year 2026.
Ellsworth AFB in South Dakota, set to be the first base to receive operational B-21 aircraft, is already advancing various infrastructure projects to ensure readiness upon their arrival.
USAF Chief of Staff General David Allvin said: “The B-21 Raider programme represents a cornerstone of our strategic nuclear modernisation.
“The concurrent efforts in testing, sustainment preparation and infrastructure investments clearly illustrate our commitment to providing unmatched capabilities to deter and defeat threats well into the future.”
Developed in collaboration with Northrop Grumman under the supervision of the Air Force Rapid Capabilities Office, the B-21 Raider represents a next-generation stealth bomber. It was designed for high survivability and penetrating strike missions.
The initial loads calibration test for the B-21 took place in May 2022 as part of ground testing. This phase involved calibrating the aircraft’s instrumentation and confirming its structural integrity ahead of its first flight in 2023. The B-21 Raider is named to honour the Doolittle Raiders, who executed a surprise attack during World War II in April 1942. (Source: airforce-technology.com)
16 Sep 25. Meltio inaugurates first international Advanced Additive Manufacturing Reference Site in the U.S. during Premiere Event:
Parts Made in USA Printed with Meltio’s Technology
Key Highlights
- Fastech’s Virginia facility is a trusted Meltio service bureau and long-time user of Meltio’s technology, showcasing advanced metal additive manufacturing (AM) for the defense, aerospace, energy, and industrial sectors worldwide.
- Ready for Action Event – October 14th, 2025: Accelerating Readiness. Sustaining the Future through Additive Manufacturing (AM). Fastech and Meltio will host an event at Fastech’s Virginia headquarters to showcase its introduction to Blue Laser technology for AM, while also celebrating a major milestone: being named the first Meltio Additive Manufacturing Reference Site in the United States. Meltio and Fastech invite partners, customers, and industry leaders to attend.
- Meltio in action: Our technology is already validated in global defense projects across Asia, Europe, and the U.S., including the USS Somerset, and is trusted by leading industrial organizations. At Fastech’s event, companies such as Siemens Energy, ExxonMobil, the U.S. Navy, the Institute for Advanced Learning and Research (IALR), Austal, and Phillips Corporation will share their experiences with Meltio. Building on this momentum, Fastech will now expand its leadership by printing parts for the U.S. Army.
- During the open house: Meltio will showcase metal applications with its industrial Blue Laser systems, the Meltio M600 metal 3D printer, and the Meltio Robot Cell. These solutions address critical challenges such as on-demand part repair in remote or operational areas, replacement of obsolete or worn-out components, battlefield damage repair, and remote tele-operation, helping defense and industry reinforce supply chains and maintain mission-critical equipment.
- The Meltio Engine Blue: Our latest breakthrough enhances reliability, speeds up production, and expands material capabilities with a powerful 1.4 kW blue laser, setting a new benchmark for industrial AM.
Meltio, a leading manufacturer of wire-laser metal additive manufacturing solutions, and Fastech, a Virginia-based provider of advanced metal additive manufacturing and machining services, today announced the official launch of its introduction from the infrared-laser–based Meltio Engine Robot Integration to Blue Laser wire metal 3D printing technology. This milestone will be celebrated with the opening of Meltio’s first international Advanced Additive Manufacturing (AM) reference site in Danville, Virginia, on October 14, 2025. Join us for this inaugural gathering, where the new facility will serve as a demonstration hub for U.S. and international industries to experience the capabilities of Meltio’s Directed Energy Deposition (DED) wire-laser metal 3D printing solutions across multiple sectors.
This site marks a major milestone in Meltio’s global expansion, highlighting the breakthrough shift from IR to Blue Laser technology. With greater performance, reliability, and scalability, this introduction sets the stage for future reference centers worldwide.
The new Meltio Reference Site will specialize in producing metal parts for sectors such as defense, aerospace, naval, education, and beyond. It highlights the value of wire-laser metal additive manufacturing in solving critical challenges: enabling on-demand repair and production in remote or operational areas, replacing obsolete or worn-out components, restoring battle-damaged equipment, and providing design flexibility for innovative parts. By reducing reliance on vulnerable supply chains and allowing remote tele-operation, Meltio delivers shorter time to part and reduced costs.
As part of this milestone, Fastech has acquired the Meltio M600 metal 3D printer and the Meltio Robot Cell, which will be fully operational and on display during the open house, showcasing Meltio’s industrial metal additive manufacturing solutions.
Advancing the Defense and Security Sector – A New Era for American Industry
Meltio’s reference site will enable manufacturers across the defense, aerospace, automotive, mining, energy, oil and gas, and research sectors to test, validate, and adopt metal AM applications. Thanks to the capabilities of Advanced Additive Manufacturing that Meltio offers, the center will help companies cut costs, speed up production, and strengthen supply chains with reliable, on-demand manufacturing. The Meltio M600 industrial system and the Meltio Engine Integration Kit for industrial robots enable the production and repair of parts in multiple materials, including copper, titanium, stainless steel, Inconel, and aluminium.
Competitive Advantages
Meltio addresses evolving demands across multiple American industries by delivering highly reliable metal 3D printing making possible Advanced Additive Manufacturing through its Blue Laser technology, offering exceptional versatility in part production, repair, durability, and feature addition. Its near-net shape approach minimizes production time and reduces material waste, making the process more environmentally friendly, setting a new standard for efficiency in additive manufacturing.
Meltio’s wire-laser Directed Energy Deposition (DED) metal additive manufacturing solutions offer higher tolerances and superior part definition compared to other similar technologies. This makes it particularly valuable for industries where precision, repeatability, and reduced lead times are critical.
Alan Pearce, CEO of Fastech, said:
“We are proud to partner with Meltio to bring this groundbreaking reference site to life. Many companies, including ours, are embracing DED technology because it enables higher tolerances, superior part definition, precision, repeatability, readiness, and reduced lead times. This site will give U.S. manufacturers the chance to experience those advantages firsthand.”
Gabriel Ortiz, Sales Manager, Meltio in the United States, added:
“Establishing this first global reference site in the United States reflects Meltio’s strong commitment to supporting U.S. industries. With Fastech, we are giving manufacturers the opportunity to explore cutting-edge applications, from defense to research, that demonstrate the transformative power of wire-laser metal 3D printing.”
Meltio Engine Blue & multi-laser Blue Deposition Head, a reliable industrial solution
The Meltio Engine Blue enhances Meltio’s metal AM solutions with increased reliability, power, and versatility using Blue Laser technology. It can print stainless steel, titanium, copper, aluminum, nickel, and other metals, producing parts with high density, precision, and repeatability for a wide range of industrial applications.
“The new Meltio Engine Blue is a breakthrough in our directed energy deposition (DED) technology, designed to meet the evolving demands of manufacturing worldwide,” says Meltio Product Manager Alejandro Nieto. “It delivers higher reliability and deposition rates, enabling faster production and superior quality. With a fiber-optic-free 1.4 kW blue laser head, integration into robotic arms and vertical machining centers is simpler, maintenance is reduced, and issues like continuous laser alignment are eliminated. This allows our customers to optimize processes, reduce downtime, and work with a broader range of materials.”
Its ease of integration and high reliability make the Meltio Engine Blue a standout solution for industrial sectors, including automotive, aerospace, energy, naval, defense, mining, and oil & gas.
Metal parts on display at Fastech’s new Reference Site during the Open House:
- Artillery Shell: Defense sector application developed by Meltio on the Meltio M600. Manufactured in SS-316LSi and Marine Bronze, it demonstrates the potential of multi-material additive manufacturing for critical defense components.
- Dual Wall Pipe: Oil & Gas sector application developed by Meltio. Produced in SS-316LSi with the Meltio Engine Robot, this part demonstrates the potential of additive manufacturing for high-strength and corrosion-resistant components in demanding energy environments.
- Engine Block: Automotive sector application developed by Polimotor. Manufactured in SS-316LSi using Meltio Engine Robot, this part showcases the potential of additive manufacturing for complex and high-performance automotive components.
- Flap Actuator: Aerospace sector application developed by Meltio. Manufactured in Titanium 64 on the Meltio M600, this component weighs only 0.67 kg, showcasing the advantages of lightweight, high-strength additive manufacturing for aerospace systems.
- Lightweight Tank Ice Cleats: Defense sector Case Study developed by Meltio with AM Solutions for the K2 Black Panther tank. Produced on the Meltio M600, these parts achieve 60% weight reduction, enhance soldier mobility, and reduce lifecycle costs, showcasing the advantages of additive manufacturing for tactical applications.
- Winglet Mould: Aerospace sector Case Study developed by CATEC in collaboration with Meltio. Manufactured in Invar using the Meltio Engine Robot, this part demonstrates high precision and thermal stability, highlighting the potential of wire-laser DED technology for the production and repair of complex aerospace tooling.
- Propeller Shaft Bracket: Naval sector application developed by Meltio. Manufactured in Marine Bronze on the Meltio M600, this part demonstrates the strength, corrosion resistance, and precision achievable with additive manufacturing for demanding maritime components.
- Jet Engine Exhaust: Aerospace sector application developed by Meltio. Manufactured in SS-316LSi using the Meltio Engine Robot, this part showcases the durability and high-temperature performance achievable with additive manufacturing for critical aerospace components.
Discover how Meltio’s Blue Laser wire-laser metal 3D printing technology can help your business reduce costs, accelerate production, and unlock new design possibilities.
About Fastech
Based in Danville Virginia, FasTech was established in 2018 to provide cutting-edge metal additive 3D printing, using the first Gefertec 3D metal printing machines in the U.S. Seven years on, we now also have a range of state-of-the-art machining centers to complete the production process on site, plus the latest equipment for reverse engineering. With its ability to offer standalone or combined rapid machining and additive 3D metal printing capabilities, FasTech’s prototyping, design for manufacture, and supply management services promise a long list of benefits for different industries in the United States.
About Meltio
Meltio is advancing metal additive manufacturing with high-performance, affordable, and easy-to-use 3D printing solutions based on wire-laser metal deposition (LMD) technology. Our new Blue Laser systems deliver highly reliable results and dense metal parts for manufacturing and repair. The portfolio includes the Meltio M600 industrial printer, the Meltio Engine Blue for CNC and robotic integrations, and the Meltio Robot Cell, a turnkey containerized solution for hybrid manufacturing. Learn more at www.meltio3d.com
15 Sep 25. DSEI 2025: Tech Zone wrap-up.
An experiment in space, DSEI’s new ‘Tech Zone’ melting pot saw SMEs present their dual-use wares among conventional defence primes. The organisers of DSEI 2025 trumpeted their extra hall space at the ExCel in London which, they said, encompassed more than 20% extra space than the previous year to situate more than a hundred additional companies. But this region of the convention centre, located apart from the main pavilions, on the east wing, reflected a unique melting pot of companies which accurately represents the defence industry right now.
It is a space that held Anduril, a frontrunner in the global defence industry, but also the likes of Amazon Web Services, a supplier of satellite and cloud services in the civilian sector.
During the event, DSEI spokesperson Neil Sexton told Army Technology that the Tech Zone represents a change in the way that the show has developed since the last exhibition in 2023.
“It’s a space that we’ve not had previously,” he said, which ten years ago exclusively contained conventional, heavy metal hardware, but now a lot of the companies are “developing artificial intelligence and roles for that inside defence equipment,” Sexton maintained.
A lot of this is coming from the civil sector as much, if not more, than the military sphere.
“We’ve always seen in defence that historically capabilities developed by militaries have then been picked up in the civil sector and expanded into other uses. That’s much more of a two-way street these days.”
Echodyne
One company situated in the Tech Zone was Echodyne, a US-based radar technology supplier, whose co-founder and chief technology officer, Tom Driscoll, discussed the company’s principal concerns in the defence and security markets.
Echodyne conceived of a new, low-cost radar architecture that reduced the size, weight and power while maintaining a phased-array beam.
Its key offerings are twofold: software-defined radars, systems that can be updated with new capabilities and improvements, and its new Rapid Deployment Kit (RPK), a system unveiled at DSEI for the first time, consisting of four radars for quick field use and designed for users with sophisticated integrators.
The proliferation of drones, not just in defence but in the civilian sector, such as critical national infrastructure, has prompted Echodyne to contribute to counter-uncrewed aerial system (C-UAS) capabilities.
“Radar is a core… sensor for counter drone and airspace in general,” Driscoll emphasised.
During DSEI, the radar provider signed a memorandum of understanding with ST Engineering, an engineering specialist, to collaborate on C-UAS technologies with an initial focus in Singapore. It is worth noting Echodyne already supplies to the “majority of European countries,” Driscoll said.
“If you’ve got a radar that has breakthrough cost performance… that has really resonated in this problem,” Driscoll observed. “The drone problem, fundamentally, is about a cost asymmetry. We’ve now got $100 drones that can threaten $10m assets.”
When asked about Echodyne’s placement in the thick of the Tech Zone, Driscoll noted that the pickings are slim:
“If you have a certain size booth, you take the spots you can get. I don’t think that this is a bad area, but it’s… not a strategic [location].
“We didn’t say we’re going to be in the Tech Zone because we’re dual-use. I wouldn’t mind being up there next to the beautiful integrations that Rheinmetall has done with our radars, and Kongsberg, and Moog, and MSI. I’ll take a 200 by a 200 booth up there.”
MARSS
Another Tech Zone neighbour is the defence network supplier, MARSS, which offers its flagship NiDAR command and control (C2) system to detect, classify, and respond to multi-domain asymmetric threats.
NiDAR is used to protect static, often military, sites. Currently, several unnamed countries based in the Middle East use the platform. However, at DSEI, the company introduced its latest NiDAR appendage, the Autonomous Mission Management (AMM) system.
The AMM system will act as a ‘middleware’ between autonomous vehicles and the C2 network. Uncrewed systems can be deployed to add another, mobile layer of protection to a fixed military installation. MARSS is already forming partnerships with uncrewed systems makers, most notably Milrem Robotics, integrating its THeMIS uncrewed ground vehicle (UGV).
Within the next 18-24 months, MARSS’ chief executive, Johannes Pinl, predicted that transition to a fully autonomous battlespace, where warfare will essentially come down to “machine vs. machine” engagements across land, sea, and air.
To this end, MARSS’ AMM is positioning for this transition in which Pinl suggested that a range of different kinds f drones will work in unison to create a holistic picture for C2. Pinl alluded to the use of tracked UGVs like THeMIS, which offer mobility, sensors, and firepower while accompanied in the air by more evasive uncrewed aerial systems (UAS) as scouts, looking ahead to idenitfy obstacles and threats to the UGVs.
Evolve Dynamics
Meanwhile, a UK-based UAS builder, Evolve Dynamics, showcased designs born out of the border patrol and civil security sector.
While based in Surrey, around 25% of the company – 50 people – are based in Ukraine where two of its key UAS designs – the medium-sized Wolfe and the nano drone Foxe – which the company unveiled at DSEI 2025, are built off the back of the innovation in the war torn country.
Foxe, meanwhile, is currently conducting trials with the British Army with further “projects ongoing” with Dstl, according to a company representative.
Meanwhile Evolve’s Skymantis 2 UAS system is its larger, and older version, which has already been deployed by the UK Border Force. Skymantis 2 conducts intelligence, surveillance, and reconnaissance missions with a one-hour flight time and optional capacity for a tethered payload which can be drpped mid-flight.
Motorola Technologies
The DSEI Tech Zone also says ‘hello moto’ to Motorola, a telecommunications company. The American company, which prizes dispersed communications and data, showcased its wares to defence users.
Particularly, business representatives noted its latest containerised solution, many of which are designed to offer the end user with multiple layers of communications in disaggreagted and private LT bubbles that can be deployed across a 100 kilometre space.
Motorola’s recently acquired business, Silvus, enahnces the concept by connecting these communications units with the mobile ad hoc networks (MAhN).
One representative confirmed that this disaggregated tactical communications solution – also known as HABLAR, or ‘to speak’ in Spanish – is currently deployed by the German Bundeswehr in a phased approach. The contract was first signed back in 2021.
Now, though, Motorola Technologies is working to bring the concept to the UK Armed Forces with an exercise scheduled for later this year.
Maxar
The Tech Zone also covers the space domain, in which Maxar Technologies dominate satellite imagery, which is utilised for coveted military intelligence.
At DSEI, the US-based company revealed that its has extended its offerings with a new software platform known as ‘Raptor’. Ultimately, the suite enables autonomous drones to navigate and extract accurate ground coordinates in the absence of GPS.
Designed for lightweight integration with any autonomous platform, Raptor products use only a drone’s native camera and Maxar’s 90 m-plus square kilometres of global 3D terrain data to help the platform navigate with extreme precision and extract accurate ground coordinates in real-time in a GNSS-denied environment. The company also introduced attendees to its new Sentry persistent monitoring suite. Sentry integrates automated multi-constellation tasking orchestration, real-time data fusion and artificial intelligence-driven analytics.n Maxar designed the capability to monitor hundreds of areas around the world to solve complex problems such as anticipating adversarial threats or protecting industrial infrastructure. nSentry products draw on Maxar’s 250+ petabyte archive of high-resolution satellite imagery collected over more than two decades. These capabilities enabled rapid identification of aircraft, ships, vehicles and railcars, object counts and classification – laying the groundwork for identifying trends and anomalies. (Source: naval-technology.com)
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Oxley specialises in the design and manufacture of advanced electronic and electro-optic components and systems for air, land and sea applications within the military sector. Established in 1942, Oxley has manufacturing facilities in the UK and USA and enjoys representation worldwide. The company’s products include night vision and LED lighting, data capture systems and electronic components. Oxley has pioneered the development of night vision compatible lighting. It offers a total package incorporating optical filters, equipment modification, cockpit and external lighting along with fleet wide upgrade services including engineering, installation, support, maintenance and training. The company’s long experience of manufacturing night vision lighting and LED indicators, coupled with advances in LED technology, has enabled it to develop LED solutions to replace incandescent and fluorescent lighting in existing applications as well as becoming the lighting option of choice in new applications such as portable military hospitals, UAV control stations and communication shelters.
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