Potential Analysis Of Flexible Small Series Production Of Spare Parts By Direct Polymer Additive Tooling

In recent decades, there has been an increasing creation of vehicle model variants and product individualization for customer needs. There is a need for a greater variety of spare parts which is leading to high requirements on their logistics. As a result of this trend, automotive production companies have to ensure the provision of many different spare parts as part of their post-fulfillment obligations. However, the surplus spare parts stock will increase the operation cost of the company. This implies the need for a more flexible approach to spare parts production and provision to improve profitability compared to existing process chains. In this research paper, the potential of flexible spare parts production and provision is discussed. For this purpose, the state of spare part production technologies and existing approaches for spare part service are analyzed regarding their technological characteristics, flexibility as well as cost structure. Following this, an approach for flexible production for spare parts with regard to its potential is analyzed and demonstrated based on three exemplary automotive use cases using additively manufactured production resources. In the casting use case, a Fused Filament Fabricated (FFF) additively manufactured speedometer screw model will be used as a sand casting form. The production of deep-drawn car body parts using polymer-based FFF forming tools is investigated in the second use case. Lastly, the production of ignition distributor caps by PolyJet Modelling (PJM) manufactured Injection Molding (PUR-RIM) molds is presented