Additive manufacturing processes and materials for spare parts

Additive manufacturing (AM) has shown to have a high potential to produce spare parts on demand. However, the use of AM to produce spare parts on demand faces challenges related to material availability, quality, part size, cost, and pre- and post-processing operations. From existing literature, most studies focus on a single use case. Other studies focus on the applications of using AM from a general perspective, rather than a specific AM process. This study attempts to close this knowledge gap by considering the AM of spare parts and processes by undertaking a thorough review of scientific articles regarding different AM processes and materials being utilised for spare parts. Current publications do not explore all potential materials that are available, and do not investigate a broad range of industrial sectors. It was also found that the tooling industry and use for rapid prototyping are largely left out. The study also showed that the use of material jetting and binder jetting are less frequently used for end-use spare parts and sheet lamination is rarely used at all. In contrast, we found that directed energy deposition was most popularly used for repairing spare parts, followed by powder bed fusion and material extrusion that are prevalent in most industries. This study revealed that further development on the use of binder jetting and material extrusion would allow for more possibilities in the use of high-value pare parts for sectors such as aerospace, automotive, energy, defence, consumer products and medical industries.