Additive manufacturing (AM) is a production process for manufacturing components using various 3D printing techniques. The range of materials that can be used is almost infinite - from innovative plastics and metal alloys to concrete, wax, resins and even human tissue. Recently, Sandvik Coromant discovered the possibility of printing with diamond powder, where the hardest material on earth is molded into the desired shape.

However, additive manufacturing processes have other advantages compared to mechanical manufacturing. For example, it is possible to print complicated and hollow shapes without waste, as only the necessary amount of material is added for the process. This has made it a popular technique in areas that require the production of highly specialized components in a small production run, such as aerospace or biomedicine, and has led to continued investment in exploring how additive manufacturing could help manage component obsolescence.

The problem of obsolescence

Our society is characterized by rapid technological developments in terms of the use of big data, automation and informatics. These technologies have had a positive impact on manufacturing, allowing plant managers to maximize productivity, reduce waste and create a safe working environment for their employees.

However, technological components, both hardware and software, tend to have a shorter lifespan. When new versions of the same components are distributed, the original equipment manufacturer (OEM) may discontinue production of the version purchased from the manufacturer, rendering it obsolete.

When obsolete components break, it can be difficult to find identical replacement parts. Obsolescence management is therefore crucial, as broken or non-functioning obsolete components can result in costly downtime for the company or require an upgrade of the entire system.

Additive manufacturing: a sensible alternative?

Material engineers are currently investigating the potential of additive manufacturing in connection with obsolescence management. The core idea is to simply additively manufacture components that are no longer available from the OEM.

For stakeholders working in highly regulated industries, where upgrading to newer components involves a lot of paperwork and bureaucracy, it is particularly important to explore this possibility. Several governments, for example in the US and Switzerland, have already launched research programs to investigate the potential of additive manufacturing to manage obsolescence within the defense industry. While the results are promising, there are still technical and bureaucratic questions that need to be answered.

One of these issues is compliance with legal regulations. From a legal perspective, it is unclear what conditions 3D printed components must meet to ensure that they are safe for use in certain applications. This is particularly true for highly regulated sectors such as the nuclear, pharmaceutical or food and beverage industries, where the use of components and the frequency of replacement are prescribed by law.

From a purely technical point of view, the biggest disadvantage of additive manufacturing is that although this technology could help with obsolescence of mechanical components, it is not clear whether this would also be the case in other areas, for example electrical engineering. Mechanical components, electronics, cables, software and know-how can all be subject to obsolescence and solutions that address only one aspect of this are only partially helpful.

A holistic approach

Obsolescence is the natural consequence of technological progress and the marketing of ever more efficient solutions. It is therefore not completely avoidable. However, its impact on the company can be drastically reduced.

There are two main approaches to obsolescence management: the reactive and the proactive. The reactive approach consists of taking action to replace or repair parts as soon as a failure occurs. The proactive approach is based on constant monitoring and planning to prevent faults from occurring in the first place.