Using additive manufacturing to transition away from OEM-repaired failures: a protection-level preservation constrained life-cycle cost model
Year: 2026
Type: article
Abstract: Additive manufacturing (AM) provides many potential benefits over conventional manufacturing (CM) for critical systems. This paper is focused on quantifying the value of the possible time savings associated with AM when supporting a fleet of critical systems. The model developed in this paper focuses on systems that currently use CM and need to be returned to their original equipment manufacturer (OEM) for repair when they fail; AM allows some failures to be resolved without requiring return to the OEM and thereby reduces the spare resupply time. The model monetizes the cost avoidance associated with using AM parts based on a constraint that the protection level provided by a spare subsystem inventory for a fleet utilizing conventional manufacturing (CM) parts equals that of a fleet employing AM parts. Protection level is the probability that at least one spare will be available in the inventory all the time. Models for single-echelon and multi-echelon sparing are developed. A case study of an Electronic Support Measures (ESM) system used in helicopter fleets deployed on aircraft carriers is provided. The results of the case study demonstrate that although manufacturing costs are larger when using AM parts, the life-cycle cost for a fleet of systems can be substantially less due to decreases in failure resolution times enabled by AM part repairs in the field.
Authors: S. P. Chen, P. A. Sandborn, T. Rovere
Language: English
Subfield: Management Information Systems
Domain: Social Sciences
Open Access status: hybrid
Estimated APC paid: $3,290
Funder: Air Force Research Laboratory
Award: G497264525
OpenAlex ID: W7129348900