The rise of additive manufacturing in spare parts production: A data-driven analysis
The spare parts industry is undergoing a revolutionary transformation through additive manufacturing (AM), commonly known as 3D printing. This technology is reshaping how companies approach spare parts manufacture, stock management, and supply chain optimisation. Recent developments and research indicate that this shift is not merely a passing trend but represents a fundamental change in manufacturing strategy.
The evolution of spare parts manufacturing
Traditional spare parts management presents several critical challenges, including long warranty and availability periods extending across decades, unpredictable demand patterns, and the need to maintain extensive stocks [1]. These challenges are particularly painful for products with long service lifetimes, where manufacturers must guarantee the availability of spare parts long after regular production has ceased.
Companies rely on four main spare parts supply strategies to ensure efficiency and availability. Compatible parts (16%) involve using interchangeable components across different systems. Final stock (17%) refers to holding a fixed quantity of parts for products nearing the end of their life cycle. Reuse/remanufacturing (22%) focuses on refurbishing used parts to extend their lifespan. Internal/external production (45%) is the most common approach, whereby companies either produce parts in-house or procure them externally to balance cost and quality. Each strategy helps optimise stock levels and minimise downtime [2]. However, all the abovementioned strategies lead to extensive warehousing and extended supply chains.
The additive manufacturing advantage
Additive manufacturing (AM) addresses traditional spare parts supply challenges by enabling economic small-batch production, decentralised manufacturing, and on-demand production close to the need. Research published in Procedia CIRP highlights that AM facilitates cost-effective production while reducing reliance on extensive inventories. These benefits streamline supply chains and lower overall stockholding costs [3].
Real-world implementation
Leading manufacturers like Daimler Buses already employ 3D printing for spare parts, integrating digital rights management to protect quality and intellectual property [6]. This approach shortens delivery times, reduces stockholding costs, and ensures part authenticity.
The United States Navy utilised AM for successful repairs during RIMPAC 2024 using Meltio’s technology [7], while Hydraulex Global adopted the Titomic D523 to enhance maintenance operations [8]. These cases demonstrate the potential of AM for on-site spare parts manufacturing, particularly in demanding environments, thereby reducing downtime and improving operational efficiency.
Economic impact and future projections
Additive Manufacturing of suitable spares holds a vast and untapped opportunity for various industries. We’ve witnessed an average saving of 9,750€ per identified component compared to conventional spare part strategies, but only for the components that should be made additively. In addition, companies adopting AM solutions report substantial improvements in supply chain efficiency, stock management, and responsiveness to urgent part requests, ultimately lowering operational costs [5]. Securing uptimes, reducing stock levels, and shortening the supply chains are the main drivers for companies to move into digital on-demand manufacturing strategies.
Challenges and considerations
Whilst AM offers considerable benefits for spare parts manufacture, its adoption requires careful consideration of several factors. Maintaining consistent quality across decentralised facilities, safeguarding intellectual property via digital rights management, and ensuring material compatibility with original specifications are essential. In addition, companies must assess when AM is genuinely more cost-effective than traditional manufacturing techniques. That’s why SelectAM was built - for companies to be able to find and qualify the “right” components for their digital manufacturing strategies.
The path forward
The integration of AM presents manufacturers with a valuable opportunity to optimise their operations. BAE Systems [9] and PwC [10] highlight the value of complex geometries, low-volume high-value parts, and legacy components with long lead times—all of which benefit from reduced costs and fewer production and supply constraints.
As predicted by PwC in 2017, the spare parts industry is undergoing significant transformation through AM technology. With advancing capabilities, declining costs, data-driven part identification, and expanding material options, this trend is only expected to accelerate in the coming years.
Solutions like SelectAM are helping companies move from analog to digital regarding spare part strategies. And if you only have technical 2D drawings of the component, SelectAM’s Leap3D will convert those drawings to 3D-models that can be used for digital on-demand manufacturing, not only 3D-printing.
Conclusion
Adopting additive manufacturing in spare parts production marks a significant shift in manufacturing strategy. With demonstrated benefits in cost reduction, lead time improvements, and supply chain optimisation, AM is well-positioned to become an increasingly essential element of spare parts management strategies.
Contact SelectAM today to discover how our platform can illuminate your path to AM excellence. Let us transform your manufacturing strategies together.
SelectAM is a leading provider of on-demand manufacturing optimisation solutions, helping businesses streamline their processes with data-driven, AI-enhanced part identification, qualification, and ordering systems. With proven success across industries and a firm commitment to continuous innovation, we are here to guide your on-demand manufacturing journey every step of the way.
References
[1] Koller, J., Häfner, R., & Döpper, F. (2022). Decentralized Spare Parts Production for the Aftermarket using Additive Manufacturing - A Literature Review. Procedia CIRP, 107, 894-901.
[2] Dombrowski, U., Wrehde, J.K., & Schulze, S. (2007). Efficient Spare Part Management to Satisfy Customers Needs. IEEE International Conference on Service Operations and Logistics.
[3] Li, Y., Jia, G., Cheng, Y., & Hu, Y. (2017). Additive manufacturing technology in spare parts supply chain: a comparative study. International Journal of Production Research, 55(5), 1498-515.
[4] Westerweel, B., Basten, R., Boer, J., & Houtum, G-J. (2021). Printing Spare Parts at Remote Locations: Fulfilling the Promise of Additive Manufacturing. Production and Operations Management, 30(6), 1615-32.
[5] SelectAM Product Documentation and Performance Metrics (2024).
[6] 3Printr. (2024). Daimler Buses Relies on 3D Printing and Digital Rights Management. Retrieved from
[7] Metal AM. (2024). Meltio technology was used to repair a US Navy vessel during RIMPAC 2024. Retrieved from
[8] Metal AM. (2024). Hydraulic acquires Titomic D523 to support maintenance and repair operations. Retrieved from
[9] BAE Systems. (2024). Additive Manufacturing: The Future of Spare Parts.
[10] PwC Strategy&. (2017). The Future of Spare Parts Is 3D: A Look at the Challenges and Opportunities of 3D Printing. Retrieved from
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