Historia de Meltio
Historia de Meltio
Sin categoría

The Meltio Story: A Global Benchmark in Metal 3D Printing

0

In a world where technological innovation often seems reserved for major global industrial hubs, some stories break the mold and prove that revolutions can ignite in the most unexpected places. Meltio, a company emerging from Linares, in Southern Spain, has successfully positioned itself as a global benchmark in metal 3D printing. This is the story of Meltio—of how a bold vision evolved into a multinational corporation leading the future of advanced manufacturing.

It all began with Ángel Llavero, a restless entrepreneur who saw additive technology not merely as a business opportunity, but as a form of revolution. His first business venture, Sicnova, laid the groundwork for what would later become Meltio: a company that, despite limited initial resources, set out to create advanced technology from scratch. Surrounded by a deeply committed technical team and guided by a clear vision, Llavero wagered on developing proprietary solutions that addressed the real-world needs of the industrial sector.

The birth of Meltio was the result of a strategic alliance between Sicnova and Additec, a US-based company wielding a disruptive technology in metal printing. Together, they created a unique solution in the market: a print head that utilizes welding wire and multiple lasers, capable of manufacturing metal parts with precision, efficiency, and at a low cost. This technology not only democratizes access to advanced manufacturing but also unlocks new possibilities for sectors such as aerospace, defense, mining, and automotive.

Since its founding in 2019, Meltio has experienced exponential growth. In just five years, it went from being a local startup to a global company present in over 50 countries, backed by an international workforce and millions in turnover. Its business model proved to be scalable, highly profitable, and adaptable to diverse industrial environments. Furthermore, its internationalization strategy has been exemplary, driven by partnerships with key distributors, a strong presence at global trade fairs, and a network of technology partners that reinforced its market positioning.

This is not just the story of a company, but of an ecosystem that successfully combined local talent, a global mindset, and cutting-edge technology. Meltio stands as proof that innovation knows no geographical boundaries when paired with leadership, perseverance, and a steadfast commitment to knowledge. Let us take a journey through the origins, evolution, and impact of a company that has redefined how the world is manufactured.

Meltio Metal 3D Printer (M600).
Meltio Metal 3D Printer (M600).

Ángel Llavero, the Visionary

Ángel Llavero López de Villalta was born in 1980 in Linares, a town in the province of Jaén, Spain. He grew up in a typical middle-class family. Despite his parents being civil servants—a background that doesn’t usually foster an entrepreneurial mindset—they always encouraged their four children to be their own bosses.

Furthermore, during that era, it was common practice to instill deep values of hard work and self-improvement in children. His parents excelled at this, so it is no surprise that their children grew up with a natural willingness to take risks. Ángel went on to study Law at the University of Jaén (1998–2002), which initially seemed to steer him toward a traditional legal career. Had a solid opportunity in that field come along, that would likely have been his path.

As fate would have it, his latent entrepreneurial spirit and his knack for identifying emerging opportunities led him down a completely different road. He could never have imagined that his future would lie in technology rather than law. Nevertheless, he remained firmly convinced that one did not need to be in a major metropolis to lead advanced technological projects.

The Birth of Sicnova: The First Company

As the story goes, a friend of Ángel’s, Javier Morales (now Head of ICT at Meltio), was watching an episode of the TV series CSI: NY and noticed that the protagonists manufactured a bullet using a 3D printer. This technology, which emerged in the early 2000s, was very recent and not yet widely known. It caught Javier’s attention so intensely that, according to Ángel, he said: “There is a machine that is going to change our lives. It is the future. Let’s go find it.” Thus, they began researching the viability, availability, and application of these printers in Spain.

The printer’s brand was visible in the show, so they contacted the manufacturer directly to request distribution rights for their products in Spain. The manufacturer imposed a single condition: they had to place an initial order of €300,000. Without hesitation, they asked for a one-month extension to gather the funds.

The Founders of Sicnova
The Founders of Sicnova

It is worth remembering that, at the time, these friends were only in their twenties. So, where were they going to get that kind of money? Well, Ángel’s older sister, Inmaculada Llavero, who had studied Business Administration and Management, and their friend Ildefonso Fuentes Rodríguez, who studied Economics and Business Sciences at the University of Granada, joined the venture. Together, the three of them set out to raise the capital through the most common channel in these scenarios: friends and family. In the startup world, this is known as FFF (Friends, Family, and Fools). Since that fell short, they applied for financial backing from local institutions such as the Provincial Council of Jaén, the City Council of Linares, and nascent support from the University of Jaén.

The fact is that, one month later, they became official distributors for the ZCorp group in Spain. On May 25, 2007, they incorporated the company Soluciones Sicnova SL, better known as Sicnova. Although the origin of the name has never been publicly disclosed, one can’t help but wonder if it was inspired by the words CSI: NY.

Inmaculada has been a fundamental pillar since the inception of Sicnova. Her profile is deeply tied to business development and team consolidation, and she has played a strategic role in human capital management. For his part, prior to Sicnova, Ildefonso Fuentes was involved in technological and industrial development projects, equipping him with solid experience in financial management and corporate administration. At Sicnova, he was responsible for structuring financial operations, managing investments, and ensuring the economic sustainability of the group.

From Distribution to In-House Product Development

The atmosphere of friendship, trust, and familiarity among the founders was essential to Sicnova’s success. The core founding team (Ángel, Inmaculada, and Ildefonso) was completed by the early involvement of two figures who proved vital: José Sánchez Pérez (Chief Operating Officer) and Agustín García Lanzas (Chief Commercial Officer), both bringing solid backgrounds in industrial operations and commercial management.

In 2008, key patents for Fused Deposition Modeling (FDM) and Stereolithography (SLA) 3D printing expired. This paved the way for the emergence of new brands and models, which Sicnova promptly added to its catalog. Concurrently, they expanded their operations into Latin America.

Leveraging the expertise accumulated from selling, installing, and maintaining third-party equipment, Sicnova decided in 2013 that it needed to develop its own products. Having greater control over the hardware and software would allow them to differentiate themselves and offer solutions better tailored to their clients’ needs. This strategic shift led to the creation of their R&D&i department.

Sicnova Website
Sicnova Website

Initially, they worked on diverse projects. For instance, in collaboration with the Sercosa medical center, they experimented with printing biocompatible surgical equipment. However, their primary objective was to build a large-format 3D printer. After managing the mechanical, electronic, extruder, software, and firmware design—and testing materials, temperatures, and finishes—they finally succeeded in creating a proprietary machine. In 2014, they built a new factory, and in March 2015, they unveiled their JCR 1000 printer at the 3D Print Show in Madrid.

The JCR 1000 was capable of manufacturing parts with a build volume of 100x60x60 cm, a precision of 50 microns, and utilizing a wide range of materials, including PLA, ABS, nylon, carbon-fiber-reinforced materials, PP, PC, HIPS, and PVA, among others. This versatility made it suitable for various industrial sectors. Consequently, their next step was creating turnkey solutions tailored to industries such as automotive, aerospace, defense, medicine, and education.

Sicnova’s client roster includes names like Airbus, Volkswagen, Ikea, ArcelorMittal, CAF, Navantia, the Spanish Air Force, and the healthcare sector through collaborations with leading companies such as HT Medical. Notably, in 2017, they launched a 3D scanner named CloneScan, which garnered significant attention within the industry and the international press.

The Birth of Meltio

Since its inception, Sicnova had managed to grow consistently, becoming a well-established company in its operating markets with a team of just 10 employees. Everything changed in 2019. ArcelorMittal, a leading global multinational in the steel and mining sector, reached out to them with a proposal. In Ángel’s words: “ArcelorMittal contacted us. We thought they wanted to buy machines from us, but they told us they had come across a small company in the United States, AddiTec, which had a concept with a highly interesting patent.”

The US company had received an order from ArcelorMittal a year prior but had failed to deliver anything due to a lack of manufacturing capacity. ArcelorMittal’s executives believed that AddiTec’s patent, combined with Sicnova’s expertise and proven track record in the 3D printing market, could be a recipe for success. It was a revolutionary metal 3D printing patent that utilized lasers and welding wire instead of the traditional metal powder, making the entire process safer, more cost-effective, and highly versatile.

Meltio is a Joint Venture between Sicnova and Additec
Meltio is a Joint Venture between Sicnova and Additec

As one might expect, Ángel did not hesitate to accept the challenge. However, believing the project would need an initial jumpstart, he set a condition. As Ángel recalls: “I told ArcelorMittal that if they placed an initial order for 10 machines, I could use that to convince the Americans to set up the company.” Sure enough, ArcelorMittal immediately approved the order for a total amount of €2 million.

Three days later, Ángel Llavero and an ArcelorMittal representative traveled to Las Vegas, USA, to present the proposal to AddiTec. Five days after that, the Americans were in Linares, Spain, to map out how it could be brought to fruition. They agreed to establish a joint venture between AddiTec and Sicnova. Meltio had just been born—a new company combining Sicnova’s expertise in additive 3D printing with AddiTec’s proprietary metal printing technology. Additive printing means that the part is built by adding material layer by layer. Sicnova made it possible for AddiTec’s patent to transform into a tangible, commercial product. It was 2019.

Meltio opened up a completely new realm of business opportunities across multiple industrial markets.

Meltio’s Revolutionary Technology

When asked what makes Meltio’s technology so revolutionary, Ángel explains that the secret lies in their patented print head, which feeds welding wire utilizing multiple lasers (multi-laser). With this technique, they are capable of manufacturing parts with the exact same quality as a traditional foundry.

Traditionally, metal 3D printing technologies operate using metal powder. As Ángel puts it, “Metal 3D printing itself is not the revolution; the revolutionary step was replacing the commonly used metal powder with wire.” This seemingly simple innovation represented a massive qualitative leap over existing printers.

Fundamentally, the advantages of using wire are as follows:

  • Safety: Under certain conditions, metal powder can become explosive and is carcinogenic, requiring operators to use full PPE (Personal Protective Equipment) during handling. In contrast, welding wire poses zero risks to operators.
  • Cost: Metal powder is considerably more expensive to manufacture than welding wire.
  • Quality: The wire provides the parts with exceptional density, comparable to traditional methods like casting, but with superior quality.
  • Versatility: Meltio’s machines can print metal parts weighing up to half a ton. In fact, they have plans to expand to even larger capacities.

Meltio calls its technology LMD (Laser Metal Deposition). The multi-laser system utilizes between 3 and 6 lasers that concentrate energy onto a single focal point, melting the metal wire to build the parts layer by layer.

Metal 3D Printing Technology
Metal 3D Printing Technology

The Rapid Growth and Consolidation of Meltio

Meltio’s operations kicked off that very same year, 2019, with a team of 10 employees. They focused entirely on manufacturing the 10 machines for the €2 million order promised to ArcelorMittal. This initial order provided the necessary financial foundation to establish operations and refine their technology.

In 2020, they faced the challenge of the COVID-19 pandemic. As Carlos Capel, Meltio’s Head of Product, explained: “We used that crisis as an opportunity to focus intensely on product development, testing, and equipment validation.” Despite the global slowdown, they recorded a turnover of €2.5 million, and the workforce grew to 25 employees.

The following year, 2021, the team expanded to 50 employees and revenue doubled to €5 million. However, the major milestone of that year was securing a contract with the United States Navy (US Navy). The Navy realized that Meltio’s 3D printers were ideal for manufacturing spare parts directly on board their vessels. They no longer needed to carry vast inventories of spare parts; having the printer on board was enough. It is worth noting that Meltio’s printers were capable of manufacturing metal components weighing up to half a ton.

Their growth continued seamlessly over the following years, cementing their position as global leaders in metal 3D printing. Here is a brief overview:

  • 2022: The company reached 90 employees and a turnover of €13 million, representing a 160% growth compared to the previous year. During this year, Meltio surpassed 300 systems sold worldwide. In October, they installed their first hybrid additive manufacturing system—a Meltio Engine integrated into a Haas CNC machine—aboard the amphibious assault ship USS Bataan.
  • 2023: Armed with 120 employees and a €20 million turnover, the company was exporting to more than 60 countries. That year, Meltio received the Spanish National SME of the Year Award (Premio Nacional Pyme del Año), presented by His Majesty King Felipe VI.
  • 2024: Maintaining its workforce at 120 employees, the company closed the year with a turnover of €30 million. The year was highlighted by the launch of the Meltio M600, their most advanced printer to date. They were also honored with the prestigious 3DPI Award, granted by the international community of additive manufacturing experts.
Metal parts printed with Meltio 3D printers
Metal parts printed with Meltio 3D printers

Product Portfolio

Meltio’s primary competitive edge is the development and commercialization of LMD (Laser Metal Deposition) technology, an advanced variant of Directed Energy Deposition (DED). Currently, Meltio’s product portfolio centers on these four core offerings:

  • M450 Printer (Launched in December 2019): A compact 3D printer for metal parts. It features a maximum build volume of 20x15x45 cm and is compatible with various metals such as Inconel, titanium, and stainless steel.
  • M600 Printer (Launched in March 2024): A next-generation metal 3D printer designed for completely autonomous, 24/7 continuous operation.
  • Meltio Engine CNC Integration (Launched in November 2020): Designed to convert traditional CNC (Computer Numerical Control) machines—which typically only perform subtractive manufacturing via material removal—into hybrid systems capable of combining traditional machining with metal 3D printing (additive capabilities).
  • Meltio Engine Robot Integration and Robot Cell (Launched in September 2023): These setups enable metallurgical additive printing on large-scale industrial robotic arms, exponentially increasing part size, geometry complexity, and integration capacity with pre-existing industrial networks.

Meltio’s product portfolio reflects a strategy of flexibility and accessibility, positioning the brand as a strategic partner in industries such as aerospace, defense, automotive, and energy. All products are fully compatible with an array of commercial metals, including stainless steels, titanium, nickel, copper, and aluminum.

Furthermore, Meltio’s R&D department, led by Lukas Hoppe, continues to pioneer new solutions, aiming to ensure that any business—regardless of its size—can capitalize on the competitive advantages of additive manufacturing.

Meltio Robot Cell machine installed in Virginia, USA.
Meltio Robot Cell machine installed in Virginia, USA.

Internationalization Model

Despite numerous opportunities to offshore production, the founders always maintained as a non-negotiable condition that the factory must remain in the province of Jaén. In Ángel’s words: “We are from Jaén, we were born in Jaén. One of the conditions we set was that the factory had to be located right here in the region, because this is where we feel comfortable and where we have our core infrastructure.”

Ángel Llavero believes that a key driver of Meltio’s success lies in combining local manufacturing with a global reach. He explains that “100% of our R&D and manufacturing activity is located in Linares (Jaén). And more than 80% of our suppliers are within less than 200 kilometers of here.” This strategy allows the company to remain insulated from many of the disruptions and conflicts impacting global supply chains, as well as rising logistics costs.

Despite its local base, Meltio’s current team of over 120 professionals in Linares comprises 10 different nationalities. The company has created a unique multicultural ecosystem within a town of just 55,000 inhabitants. This international diversity injects global perspectives into the company while preserving a deeply rooted local identity.

Its global mindset in commercial operations has enabled over 96% of its turnover to derive from international trade. The company operates in more than 60 countries through a solid network of local distributors and integrators who embed Meltio’s technology into their clients’ industrial robots and CNC (Computer Numerical Control) machines. Additionally, it has established sales and after-sales support offices in the United States, India, Italy, Germany, and Poland.

This robust infrastructure has won them prestigious clients, including the United States Navy (US Navy), the French Navy, and the Spanish Ministry of Defense, alongside industrial multinationals like Siemens, Philips, Airbus, Volkswagen, and ArcelorMittal. Furthermore, companies such as Iveco, DMG Mori, Stellantis, and others have validated Meltio’s technology for developing and manufacturing custom components, achieving a drastic reduction in costs and lead times.

As previously highlighted, Meltio’s machines can process a wide variety of metallic materials, including different grades of steel, titanium, nickel, and copper. This exceptional material versatility ensures their printers deliver immense value across a vast range of sectors, including automotive, aerospace, defense, maritime, mining, oil, and gas.

Meltio Internationalization (2024).
Meltio Internationalization (2024).

Meltio’s Business Model

To date, Meltio has exercised notable caution regarding external equity capital, strictly prioritizing organic and sustainable growth. While companies of this nature are typically backed by massive industrial conglomerates, venture capital giants, or successive funding rounds, Meltio has cleverly capitalized on emerging opportunities to finance itself. This has been achieved primarily through strategic industrial partnerships and significant initial orders from major clients. This order-backed financing model has provided the company with financial stability and solid market validation right from the outset.

Nevertheless, Meltio has also received institutional backing. The Provincial Council of Jaén, through its Employment and Business Plan, granted Meltio nearly €1.3 million in subsidies. Spain’s Ministry of Science and Innovation invested €1.5 million in the company, recognizing its potential to drive the country’s industrial infrastructure. In 2024, Meltio secured €1 million in European funds from the EU Recovery Plan for 3D printing initiatives. Separately, Sicnova also obtained €500,000 to develop a biomethane project utilizing 3D-printed microreactors.

Meltio’s initial success—fueled by large industrial orders, institutional grants, strict cost control, and, above all, a steadfast commitment to reinvestment—has allowed the company to preserve a strategic independence rarely seen in tech startups. As a result, the founders still retain the bulk of the ownership, granting them the freedom to make long-term decisions without external pressure. This has enabled them to maintain absolute leadership over product development and commercial strategy.

Meltio’s core business activity centers on the direct sale of machinery to industrial enterprises and providing customized solutions to seamlessly integrate this machinery into existing production lines. It operates entirely as a B2B (business-to-business) company. For its commercial distribution, it relies on authorized integrators and distributors across various continents. These integrators are responsible for tailoring Meltio’s technology to the specific operational needs of each client.

Additionally, Meltio drives ancillary revenue through custom project development and ongoing after-sales technical support. This approach fosters stable, high-trust relationships with clients, encouraging them to return to the company whenever they need to upgrade or scale their equipment—whether through software updates, adding new functionalities, or purchasing more advanced hardware models.

Consequently, the business model combines revenue streams from hardware sales, technical consulting, and software/automation integration. Continuous incremental innovation, flexibility, and a laser focus on high-value-added sectors (defense, automotive, mining, energy) ensure profit margins that sit well above the average for the traditional industrial machinery sector.

It is also worth noting that employee turnover at Meltio is remarkably low, a factor that Ángel considers fundamental to their trajectory. “Employee turnover is very low across the entire group, and ultimately, this is a collective success belonging to all the workers who have been or are currently part of the company,” he points out.

Meltio's Financial and Operational Evolution (Source: Internet).
Meltio’s Financial and Operational Evolution (Source: Internet).

Conclusions on the Meltio Miracle

The story of Meltio represents far more than the success of a technology company. It stands as definitive proof that, from a small town of 55,000 inhabitants in Jaén, combining local talent, a global mindset, and technological innovation can birth a company that leads a global industrial sector.

The “Meltio Miracle,” as it has been dubbed by various media outlets, lies in the alignment of several unique factors: the visionary ability of its founders to identify disruptive opportunities, the technical excellence of their patented technology, a steadfast territorial commitment that preserves high-quality production and employment locally, and a global ambition that has driven their technology into more than 60 countries.

From that single episode of CSI that inspired the creation of Sicnova to becoming an official supplier to the US Navy and winning international accolades, Meltio’s trajectory proves that innovation, perseverance, and strategic vision can transform an idea into an industrial reality capable of reshaping entire sectors. Ultimately, the primary drivers that have catapulted this company to the global forefront are:

  • Entrepreneurial Vision: Meltio’s founders proved that business vision can be just as crucial as technical expertise. From Sicnova’s early days sparked by the CSI anecdote to the bold proposal made to ArcelorMittal, the knack for identifying opportunities and taking calculated risks has been the common thread in their success.
  • A Distinct Growth Model: By bypassing traditional venture capital funding rounds in favor of self-funded organic growth, Meltio has retained absolute control over its corporate strategy. They have proved that a robust business model can generate the capital necessary for global expansion. This conscious choice reinforces the company’s profitability and long-term sustainability.
  • Strategic Partnerships: Meltio’s impressive global market penetration has been achieved by building a rock-solid ecosystem of distributors and strategic partners. Pivotal collaborations, such as their alliance with Phillips Corporation for the US defense sector or their agreement with the Spanish Ministry of Defense, have served as ultimate validations, unlocking access to the most demanding markets.

The company has not only revolutionized the way metal components are manufactured; it has established a unique corporate blueprint that seamlessly merges technological excellence, social commitment, and regional roots—proving that it is entirely possible to be global from a local base and that homegrown talent can spearhead cutting-edge technological sectors worldwide.

Ángel Llavero and his team have achieved something unprecedented, but the Meltio story is still being written.

Meltio: Innovation from Jaén.
Meltio: Innovation from Jaén.

Bibliography

Although the content of this blog is intended for educational and informative purposes, we take data verification very seriously. Our articles are the result of interviews with key figures and industry experts, as well as meticulous research across official sources, media outlets, scientific publications, and in-depth reports. Because of this, the stories we share are often recognized by their own protagonists as highly accurate. In any case, if you spot any errors or inaccuracies, we would be incredibly grateful if you could leave a comment at the end of the article or let us know at blog@carballar.com.

However, as a non-profit, educational blog, we operate with a lean approach, which means we cannot dedicate the time required to exhaustively reference every single piece of data presented. Nevertheless, should you need to verify any of the figures or information, we have attached some of the primary sources utilized below. Please keep in mind that, since this is a Spanish company, the majority of these sources are in Spanish.

Leave a Reply

Your email address will not be published. Required fields are marked *