Global energy giant ExxonMobil has transitioned a cabinet protective component in its refinery from traditional manufacturing to metal 3D printing. The original part had design flaws and was heavy; engineers selected Ti-6Al-4V titanium alloy and used Meltio wire laser metal deposition (DED) technology to significantly reduce weight and cost. The part must prevent oil from entering sensitive system panels via capillary action while withstanding continuous vibrations during system operation. The base design features a maximum overhang of 75 degrees, using a non-planar printing strategy to avoid complex support structures. The key process challenge was hot metal oxidation, solved by extending cooling intervals during parallel production and locally reducing laser power and wire feed rate. A project participant concluded: 'Before wire DED, titanium alloy was almost impossible as an option due to high cost, but Meltio technology has made it feasible.' This case demonstrates that laser metal deposition (LMD) is not only suitable for prototypes but also for reliable replacements and functional parts in industrial systems, opening new applications for titanium alloys in the energy sector.