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MeltControl
MeltControl uses micro-thermal simulation to automatically optimize every scan vector in your build. Physics-based. Localized. Validated.
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THE PROBLEM

Static parameters weren’t built for dynamic processes

Metal AM is a highly dynamic welding process. Every point in your build sees different thermal conditions – yet the entire industry relies on one-size-fits-all parameters from single coupon experiments.
⚠

Build failures & defects

Overheating in thin walls, lack of fusion, and cracking at — all because static parameters can’t adapt to changing conditions within a single part.

⏱

Weeks of iteration

Engineers spend weeks running DOEs, tweaking zones, and reprinting — burning expensive machine time and powder just to approximate workable parameters.

Excessive support structures

Without precise thermal control, conservative support strategies are the only safe option — adding material waste, post-processing time, and design constraints.

THE MELTCONTROL WAY

Physics replaces guesswork – at every single scan vector

MeltControl runs a micro-thermal simulation of your entire build and adjusts laser power and timing automatically. It “knows” the temperature at the exact point where laser hits powder.

THE MELTCONTROL WAY

Physics replaces guesswork – at every single scan vector

MeltControl runs a micro-thermal simulation of your entire build and adjusts laser power and timing automatically. It “knows” the temperature at the exact point where laser hits powder.
Micro-Thermal Simulation
Predicts temperature at every laser-powder interaction point. Not a geometric approximation – real thermal physics.

 

Automatic Power Adaptation
Dynamically adjusts energy input to maintain constant melt-pool size and sufficient welding – whether you’re in bulk, thin walls, or low overhangs.
First-Time-Right Builds
Eliminates the iterative DOE cycles. Simulation-driven optimization means your first print matches your intent.
Geometries Previously Impossible
Low overhangs without supports, complex lattices, and full-plate builds that would have failed with static parameters.

30+

Validation prints

2+

Years of R&D

0

Additional build time required

HOW IT WORKS

Three steps. Zero guesswork.

MeltControl integrates seamlessly into your existing 3DXpert workflow.
Enable it, and the physics takes over.

Prepare Your Build

Set up your parts, supports, and slicing in 3DXpert as you normally would. No special configuration needed.

Enable MeltControl

Toggle MeltControl on. The micro-thermal simulation runs automatically, analyzing every layer and adapting every scan vector locally.

Print with Confidence
Every scan vector is now thermally optimized. Constant melt-pool size, sufficient welding, reduced supports – automatically.

Before & After MeltControl

OT Camera — MeltControl not applied

WITHOUT MELTCONTROL

✕

 

Static ParametersSame laser settings everywhere – regardless of local thermal conditions

✕

 

Expert-DependentRequires extremely experienced users with deep process understanding

✕

 

Weeks of DOEsMultiple prints and years of trial-and-error to get parameters right

✕

 

Geometry GuessworkGeometric approximations that break with new parts, materials, and conditions

✕

 

Excessive SupportsConservative support strategies as safety net for unpredictable thermal behavior
OT Camera — MeltControl applied

WITH MELTCONTROL

✓

 

Physics-Based AdaptationLaser parameters tuned at every scan vector based on micro-thermal simulation

✓

 

Automated OptimizationWorks out of the box – no expert knowledge required to achieve optimal results

✓

 

First-Time-RightSimulation-driven approach eliminates iterative print cycles

✓

 

Real Thermal PhysicsAdapts dynamically to any geometry, material, and thermal condition

✓

 

Minimal SupportsOverhangs as low as 9° without supports – and without build failure risk

BUILT FOR YOUR ENTIRE TEAM

Value at every level

AM ENGINEERS & OPERATORS

“I can focus on design instead of parameter tweaking.”

Stop spending weeks on DOEs and zone configurations. MeltControl automates parameter optimization so you can focus on throughput and quality.

ENGINEERING MANAGERS

“First-time-right builds with fewer expert hours.”

Reduce build failures, cut support structures, and get parts qualified faster – without needing a thermal simulation PhD on your team.

BUSINESS LEADERS

“Lower cost-per-part and new revenue from impossible geometries.”

Fewer failed builds, less powder waste, faster time-to-production – and applications your competitors simply cannot print.

Ready to see MeltControl on your parts?

Our team will onboard you, answer your questions, and show you what physics-based optimization can do for your production.
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