A Review of Automotive Spare-Part Reconstruction Based on Additive Manufacturing

In the Industry 4.0 scenario, additive manufacturing (AM) technologies play a fundamental role in the automotive field, even in more traditional sectors such as the restoration of vintage cars. Car manufacturers and restorers benefit from a digital production workflow to reproduce spare parts that are no longer available on the market, starting with original components, even if they are damaged. This review focuses on this market niche that, due to its growing importance in terms of applications and related industries, can be a significant demonstrator of future trends in the automotive supply chain. Through selected case studies and industrial applications, this study analyses the implications of AM from multiple perspectives. Firstly, various types of AM processes are used, although some are predominant due to their cost-effectiveness and, therefore, their better accessibility and wide diffusion. In some applications, AM is used as an intermediate process to develop production equipment (so-called rapid tooling), with further implications in the digitalisation of conventional primary technologies and the entire production process. Secondly, the additive process allows for on-demand, one-off, or small-batch production. Finally, the ever-growing variety of spare parts introduces new problems and challenges, generating constant opportunities to improve the finish and performance of parts, as well as the types of processes and materials, sometimes directly involving AM solution providers

Additive manufacturing for the spare part management of classic cars

Thesis (MEng)--Stellenbosch University, 2022.ENGLISH ABSTRACT: The maintenance of older vehicles can be challenging since the supply of spare parts by the original equipment manufacturer is not guaranteed throughout the lifespan of a vehicle. Thus, there is a need to improve the current spare part supply chain for the automotive industry specifically for outdated products like classic cars. Within the automotive industry additive manufacturing (AM) technology is already being implemented in the production cycle of new cars. The need to improve the supply of spare parts for classic cars and the increased use of the AM technology raised the question whether additive manufacturing can have an impact on the spare part management of classic cars. In order to answer this question, this research study started with the review of literature. Three critical scoping literature reviews were undertaken to analyse the current performance of the spare part management of classic cars and to identify spare part attributes for the ranking of spare parts according to their potential for additive manufacturing. To fully understand the spare part management of classic cars, a first literature study on the classic car market was conducted. A second literature review on spare part management within the automotive industry utilized a performance measurement model to measure the impact of adopting additive manufacturing. Based on this, the applicability of additive manufacturing was the subject of the third literature review. Results show that a potential for additive manufacturing exists, and it can be measured with spare part attributes. Based on these results, it was decided to follow an exploratory research design approach. A survey was conducted with classic car owners to identify sourcing problems of spare parts and to assess their willingness to adopt additive manufacturing. The data from the survey was analysed using a ranking methodology from science which was modified toward the application of additive manufacturing on the spare part management of classic cars. The outcome of the ranking highlighted that small parts (e.g. switches) and batches are best suitable for additive manufacturing. A Delphi survey with subject-matter experts validated the ranking method. A case study was carried out in which a speedometer gear was reverse-engineered, additive manufactured and tested under realistic conditions. The case study highlighted that additive manufacturing is feasible to produce spare parts on demand and on a decentralized implementation strategy. Overall, this research has shown that additive manufacturing has a high potential to impact the spare part management of classic cars. The research result showed that unsatisfied customer demand is recognised. Additive manufacturing is a technologically feasible solution to produce many spare parts and has the high potential to increase the supply chain performance of classic car spare parts.AFRIKAANSE OPSOMMING: Die instandhouding van ouer voertuie kan uitdagend wees aangesien die verskaffing van onderdele deur die oorspronklike toerusting vervaardiger nie deur die lewensduur van 'n voertuig gewaarborg word nie. Daar is dus 'n behoefte om die huidige onderdele-voorsienings ketting vir die motorbedryf te verbeter, spesifiek vir verouderde produkte soos klassieke motors. Binne die motorbedryf word additive manufacturing (AM) tegnologie reeds in die produksie siklus van nuwe motors geïmplementeer. Die behoefte om die verskaffing van onderdele vir klassieke motors te verbeter en die verhoogde gebruik van die AM-tegnologie het die vraag laat ontstaan of bykomende vervaardiging 'n impak op die onderdelebestuur van klassieke motors kan hê. Drie kritiese literatuur oorsigte is onderneem om die huidige prestasie van die onderdele bestuur van klassieke motors te karteer. Eerstens is 'n literatuuroorsig oor die klassieke motormark gedoen. Die volgende twee literatuur oorsigte oor onderdele bestuur binne die motorbedryf en bykomende vervaardiging vir motoronderdele het 'n prestasie metings model gebruik om die impak van die aanvaarding van bykomende vervaardiging te meet. Resultate toon dat 'n potensiaal vir bykomende vervaardiging bestaan. Op grond van hierdie resultate is daar besluit om 'n verkennende navorsings ontwerp benadering te volg. ’n Opname is met eienaars van klassieke motors gedoen om die verkrygings probleme van onderdele te identifiseer en om hul gewilligheid om bykomende vervaardiging aan te neem, te bepaal. Die data van die opname is ontleed deur gebruik te maak van 'n rangorde metodologie uit die wetenskap wat aangepas is na die toepassing van bykomende vervaardiging op die onder delebestuur van klassieke motors. Die uitkoms van die rangorde het beklemtoon dat klein onderdele (bv. skakelaars) en groepe die beste geskik is vir bykomende vervaardiging. 'n Delphi-opname met vakkundiges het die rangorde metode bekragtig. ’n Gevallestudie is uitgevoer waarin ’n spoed-meterrat omgekeerd ontwerp is, ´n bymiddel vervaardig en onder realistiese toestand getoets is. Die gevallestudie het beklemtoon dat bykomende vervaardiging haalbaar is om onderdele op aanvraag en volgens 'n gedesentraliseerde implementering strategie te vervaardig. Oor die algemeen het hierdie navorsing getoon dat bykomende vervaardiging 'n hoë potensiaal het om die onderdele bestuur van klassieke motors te beïnvloed. Die navorsings resultaat het getoon dat die onbevredigde vraag erken word. Bykomende vervaardiging is 'n tegnologiese haalbare oplossing om baie onderdele te vervaardig en het die hoë potensiaal om die voorsienings ketting prestasie van klassieke motoronderdele te verhoog.Master

Additive manufacturing for the automotive industry: on the life-cycle environmental implications of material substitution and lightweighting through re-design

The automotive sector has recently been taking measures to reduce fuel consumption and greenhouse gas emissions for the mobility of ground vehicles. Light-weighting, via material substitution, and the re-designing of components or even a combination of the two, have been identified as a crucial solution. Additive manufacturing (AM) can be used to technologically complement or even replace conventional manufacturing in several industrial fields. The enabling of complexity-for-free (re) designs is inherent in additive manufacturing. It is expected that certain benefits can be achieved from the adoption of re-design techniques, via AM, that rely on topological optimisation, e.g., a reduced use of resources in both the material production and use phases. However, the consequent higher specific energy consumption and the higher embodied impact of feedstock materials could result in unsustainable environmental costs. This paper investigates the case of the light-weighting of an automobile component to quantify the outcomes of the systematic integration of re-designing and material substitution. A bracket, originally cast in iron, has been manufactured by means of a powder bed-based AM technique in AlSi10Mg through an optimized topology. Both manufacturing routes have been evaluated through a comparative Life Cycle Assessment (LCA) within cradle-to-grave boundaries. A 69%-lightweighting has been achieved, and the carbon dioxide emissions and energy demands of both scenarios have been compared. Besides the use-phase-related savings in terms of both energy and carbon footprint due to the lightweighting, the results highlight the environmental trade-offs and prompt the consideration of such a manufacturing process as an integral part of sustainable product development

Additive Manufacturing Technology for Spare Parts Application: A Systematic Review on Supply Chain Management

Additive manufacturing (AM) is gaining interest among researchers and practitioners in the field of manufacturing. One major potential area of AM application is the manufacturing of spare parts, which affects the availability of the operation and supply chain. The data show that the application and adoption of AM has contributed to a reduction in lead times and inventory, which also contributes to a reduction in holding costs. This paper provides a review of recent work on the application of AM technology specifically for spare parts. The review shows that there are supply chain opportunities and challenges to the adoption of AM in spare parts within various application sectors. Our research reviews both the quantitative and qualitative models used for analysis to meet the emerging needs of the industry. The review also shows that the development of technology and its application is still emerging; therefore, there will be further opportunities to develop better spare parts supply chains to support AM applications. This paper concludes with future research directions. 2022 by the authors. Licensee MDPI, Basel, Switzerland.Acknowledgments: This study was made possible by the Qatar University grant# M?QJRC?2020?6. The APC was made possible through student grant #QUST?1?CENG?2022?302. The findings of this study are solely the responsibility of the authors.Scopus2-s2.0-8512929378

Understanding how additive manufacturing influences organizations’ strategy in knowledge economy

Industry 4.0 constituted a trigger to a new phase in the Industrial Revolution, heavily focused in the interconnectivity of the systems, bringing disruptive technologies such as Additive Manufacturing (AM). On top of that, the shift from an industrial economy to a knowledge-based economy, where knowledge is the actual raw material, is implicating changes on the labor market, as new jobs strongly rely on knowledge-intensive activities. This is forcing organizations to rethink their way to operate, since markets are getting even more competitive and susceptible to greater volatility. Herewith organizations are resorting to AM as way to strengthen competitive position, as this technology allows to seize new opportunities. As response to that, this paper presents an industry analysis to AM based on Porter’s Five forces model, where forces such as threat of new entrants, bargaining power of customers, threat of substitutes, bargaining power of suppliers and rivalry among the existent competitors will be discussed under a knowledge perspective. The compiled evidence show that AM industry will plausibly suffer from a high rivalry in the next few years, as consequence of the increased power of customers and suppliers, low entry barriers for new entrants and due to pressures for a more sustainable society. Although these forces will not be totally controllable, organizations can plan their business strategy according to the knowledge they have on them. This type of approach will allow organizations to influence these forces more closely and at the same time to predict possible scenarios, identify tendencies and map the sector. In the present paper is proposed a conceptual model based on Porter’s five forces to analyze the impact of AM on firms’ strategy. For future development this model will be extended to organizations operating with AM in Portugal for validating its practical applicability, which will be performed through questionnaire and/or case study.info:eu-repo/semantics/publishedVersio

A Porter’s Five Forces Model Proposal for Additive Manufacturing Technology: A Case Study in Portuguese industry

Industry 4.0 constituted a trigger to a new phase in the Industrial Revolution, heavily focused on the interconnectivity of the systems, bringing disruptive technologies such as Additive Manufac-turing (AM). On top of that, the shift from an industrial economy to a knowledge-based economy, where knowledge is the actual raw material, implies changes in the labor market, as new jobs strong-ly rely on knowledge-intensive activities. This forces organizations to rethink their way of operating, since markets are getting even more competitive and susceptible to greater volatility. Herewith or-ganizations, are resorting to AM to strengthen their competitive position, as this technology allows them to seize new opportunities. As a response to that, this dissertation presents an industry analysis to AM based on Porter’s Five Forces model, where forces such as the threat of new entrants, bar-gaining power of customers, the threat of substitutes, bargaining power of suppliers and rivalry among the existent competitors will be discussed under a knowledge perspective. To validate the proposed model's practical applicability, a case study was conducted based on a questionnaire that was applied to organizations operating with AM in Portugal. The information collected on the ques-tionnaire supplied the forces of the proposed model. After the analysis was possible to conclude that all the participating firms, except one, fit in the incremental stream of development as regards to Additive Manufacturing technology: Closed-incremental stream, in this stream AM technologies ap-pear as a complementing tool. Regarding the case study results, the participating firms seem to expe-rience the low capability to capture specialized workforce for AM, high capital requirements to enter the market and low IPR regulation. AM brings an opportunity for higher bargaining power to arise due to 'prosumerism', yet it does not add value as a tool for the standard products industry. Moreo-ver, suppliers strongly influence sectors' competition, which will presumably suffer from increased rivalry tensions. For future development, the study of the developed model in a corporate environ-ment where the adoption of the Additive Manufacturing technology is at a more advanced level is suggested.O despoletar da Indústria 4.0 desencadeou uma nova fase da Revolução Industrial, fortemente ligada à interconectividade dos sistemas, fomentado o aparecimento de tecnologias de carácter disruptivo como o Fabrico Aditivo (FA). Para além disso, a transição de uma economia material para uma economia baseada no conhecimento, onde o conhecimento é a matéria-prima, tem implicado mudanças ao nível dos mercados de trabalho, onde as novas tarefas dependem agora de atividades intensivas de conhecimento. Uma vez que os mercados estão cada vez mais competitivos e suscetí-veis a grande volatilidade, as organizações têm sido forçadas a repensar o seu modo de operar. Para isso têm recorrido ao FA, que se apresenta como um meio para reforçar a sua posição competitiva e aproveitar novas oportunidades. Por forma a responder a este problema, esta dissertação apresenta uma análise da indústria, segundo uma perspetiva de conhecimento, aplicada ao FA baseada no Mo-delo das Cinco Forças de Porter, onde as forças analisadas são a ameaça de novos entrantes, poder de negociação dos clientes, ameaça de substitutos, poder de negociação dos fornecedores e rivalida-de entre os concorrentes. Para validação do modelo proposto, foi realizado um estudo de caso atra-vés da aplicação de um questionário a empresas que operam com o FA em Portugal. Depois da análi-se efetuada a essa informação foi possível concluir que todas as empresas que participaram do estu-do, exceto uma, se encontram numa fase incremental da adoção da tecnologia de FA, onde as tecno-logias de FA surgem como ferramentas complementares à produção. Em relação ao estudo de caso, as empresas participantes experienciam dificuldades em recrutar trabalhadores qualificados na área do FA, elevados investimentos para entrar no mercado e baixo controlo quanto a direitos de Propri-edade Intelectual. O FA proporciona o aumento do poder de negociação dos clientes, como conse-quência do 'prosumerismo', no entanto não acrescenta valor como ferramenta para a produção de produtos standard. Os fornecedores detêm grande influência sobre os setores, que presumivelmente sofrerão de elevadas tensões de rivalidade. Como proposta de trabalho futuro sugere-se a extensão deste estudo a um ambiente corporativo, onde a situação de adoção do FA esteja mais avançada

Stress-Based Lattice Structure Design for a Motorbike Application [version 2; peer review: 2 approved]

Background The “drive by wire” mechanism for managing the throttle is not applied to every modern motorcycle, but it is often managed through a steel wire. Here, there is a cam on the throttle control. Its shape allows the throttle opening to be faster or slower and its angle of rotation, required for full opening, to be greater or less. The maximum angle a rider’s wrist can withstand depends on numerous musculoskeletal mobility factors, often limited by falls or surgery. Methods Using a Progrip knob with interchangeable cams allows the customization of a special cam profile, to ensure the best engine response to throttle rotation and ergonomics for the rider. The use of FEA software and lattice structures, allows to realize a lightweight and efficient design, targeted for fabrication with additive manufacturing technologies. Results The cam was manufactured by exploiting MSLA technology. Finally, a dimensional inspection procedure was performed before assembly. The main result is to have obtained a lighter and cheaper component than the original. Conclusions This study has allowed the design of a mechanical component consisting of innovative shape, light weight, and ergonomics. Furthermore, it demonstrates the effectiveness in the use of lattice structures to enable weight optimization of a component while minimizing the increase in its compliance

Proceedings of the 2nd Conference on Production Systems and Logistics (CPSL 2021)

Proceedings of the CPSL 202

Systemic Circular Economy Solutions for Fiber Reinforced Composites

This open access book provides an overview of the work undertaken within the FiberEUse project, which developed solutions enhancing the profitability of composite recycling and reuse in value-added products, with a cross-sectorial approach. Glass and carbon fiber reinforced polymers, or composites, are increasingly used as structural materials in many manufacturing sectors like transport, constructions and energy due to their better lightweight and corrosion resistance compared to metals. However, composite recycling is still a challenge since no significant added value in the recycling and reprocessing of composites is demonstrated. FiberEUse developed innovative solutions and business models towards sustainable Circular Economy solutions for post-use composite-made products. Three strategies are presented, namely mechanical recycling of short fibers, thermal recycling of long fibers and modular car parts design for sustainable disassembly and remanufacturing. The validation of the FiberEUse approach within eight industrial demonstrators shows the potentials towards new Circular Economy value-chains for composite materials

Systemic circular economy solutions for fiber reinforced composites

This open access book provides an overview of the work undertaken within the FiberEUse project, which developed solutions enhancing the profitability of composite recycling and reuse in value-added products, with a cross-sectorial approach. Glass and carbon fiber reinforced polymers, or composites, are increasingly used as structural materials in many manufacturing sectors like transport, constructions and energy due to their better lightweight and corrosion resistance compared to metals. However, composite recycling is still a challenge since no significant added value in the recycling and reprocessing of composites is demonstrated. FiberEUse developed innovative solutions and business models towards sustainable Circular Economy solutions for post-use composite-made products. Three strategies are presented, namely mechanical recycling of short fibers, thermal recycling of long fibers and modular car parts design for sustainable disassembly and remanufacturing. The validation of the FiberEUse approach within eight industrial demonstrators shows the potentials towards new Circular Economy value-chains for composite materials