Eurobearings has strengthened its position in large-scale component manufacturing and repair by integrating Meltio’s industrial metal 3-D printing technology into its Italian production operations. The move marks a significant shift for the Cortemaggiore-based specialist, which has spent nearly three decades designing and manufacturing critical bearing systems for global OEMs operating in some of the world’s most demanding industrial environments.
Heavy industry depends on the uninterrupted performance of massive rotating equipment, from turbines to cement mills, where unplanned downtime can result in immediate and substantial financial losses. Eurobearings focuses on white metal sliding, thrust and combined bearings, components that are often extremely large, highly customised and subject to intense mechanical and thermal loads. Traditionally, producing these parts has relied on casting or machining from solid metal blocks, a subtractive process that can generate material waste of up to 80% and impose long, inflexible lead times.
To overcome these constraints, Eurobearings has installed the Meltio Engine Robot Integration, a wire-laser directed energy deposition system designed for industrial environments. The technology allows the company to deposit white metal, commonly known as babbitt, as well as other metal alloys, directly where material is required.
At the heart of the installation is a large-format KUKA industrial robot, mounted on a mobile gantry that dramatically expands its working envelope. This configuration enables the deposition head to be positioned precisely over very large or complex components, effectively removing the size limitations associated with conventional additive manufacturing systems.
According to the company, the impact on production efficiency has been immediate. By printing directly onto parts and reducing the amount of downstream machining required, Eurobearings has cut lead times for complex components by between 30 and 50%. Material efficiency has also improved markedly. The Meltio process uses standard welding wire as its feedstock, enabling near-net-shape manufacturing that ensures almost all deposited material becomes part of the finished component. This approach significantly reduces raw material consumption and lowers the overall cost per part.
One of the most transformative advantages has been in repair and refurbishment. Rather than scrapping heavily worn or damaged components, Eurobearings can now rebuild critical surfaces directly onto existing parts with high precision. This capability extends the service life of high-value components and delivers major cost savings, particularly for customers in the marine and defence sectors, where replacement parts are expensive and lead times can be lengthy.
The added flexibility is supporting Eurobearings’ work across energy, oil and gas, marine, defence, cement and rolling mill applications, where components must meet rigorous quality and performance standards. At the same time, reducing material waste and prioritising repair over replacement aligns with broader sustainability goals, lowering the environmental footprint associated with heavy industrial manufacturing and maintenance.
With its robotic directed energy deposition cell delivering a stable, repeatable, industrial-grade process, Eurobearings is positioning itself at the forefront of advanced manufacturing for large-scale rotating equipment, combining traditional bearing expertise with next-generation metal additive manufacturing technology.
Leave a comment