In a world where sustainability, efficiency and innovation go hand in hand, additive manufacturing is at the forefront of transforming the maintenance industry. “We can repair instead of replace, extend the life of components and even improve them,” says Marie-Louise Bergholt, head of the Application Centre for Additive Manufacturing at RISE.

One of the hottest topics in the maintenance industry right now is how advanced manufacturing methods can revolutionise the way we view maintenance, repair and warehousing. Additive manufacturing, commonly referred to as 3D printing, is a manufacturing process in which a component, such as a spare part, is built up layer by layer. This technology makes it possible to create both simple and complex parts in many different materials, shapes and designs. Unlike traditional subtractive manufacturing, additive manufacturing is based on adding material rather than removing it, which significantly reduces material waste, leading to lower material costs and higher resource utilisation.

The Application Centre for Additive Manufacturing at the RISE research institute is a member-based collaboration with industry and academia. Marie-Louise Bergholt and her team are working to develop and industrialise additive manufacturing in order to streamline production, maintenance and repair within Swedish industry.

– By combining research and practical application, we help companies reduce material waste, improve sustainability and optimise spare parts supply through digital warehouses and on-demand production. The centre, located in Mölndal, serves as an innovation platform where industry can test and implement the latest technologies in additive manufacturing, Marie-Louise says.

Digital warehouses and smart spare parts management

One of the biggest problems in industrial maintenance is the storage of spare parts.

– Instead of ordering a thousand parts and hoping they will be needed in the future, we can now create digital warehouses where we store design files and manufacture components on demand, Marie-Louise explains.

She continues:

– This means we can send a file to a 3D printer on the other side of the world and manufacture the part where it is needed, instead of shipping physical goods over long distances.

This strategy not only changes the cost picture, but also has enormous sustainability benefits. Reduced warehousing and production of only those parts that are actually used means less material waste and lower carbon dioxide emissions.

A future focused on repair – from a broken propeller to full functionality

One of the most striking demonstrations of the power of additive manufacturing involves a propeller.

– We got hold of a broken propeller with damage to the outer edge. In the past, this would have had to be replaced entirely, resulting in long delivery times and high costs. Instead, we scanned it, milled off the damaged part and rebuilt it layer by layer using metal powder and laser melting. After a few days’ work, it was fully functional again, Marie-Louise says.

This is just one example of how 3D printing can be used to restore machine parts to full functionality quickly and cost-effectively. The technology not only reduces the need for new components, but also shortens lead times and utilises local resources at a time when global supply chains are increasingly uncertain.

In addition to spare parts and repairs, additive manufacturing has also begun to be used in the construction industry. Marie-Louise describes a project in which 3D-printed moulds made from recycled plastic were used in the renovation of a historic building:

– Instead of making disposable wooden moulds, which creates a lot of waste, we helped a construction company print modular plastic moulds that could be used over and over again. This saved materials and time, and made it possible to recreate the beautiful details found in the original building.

Future challenges and opportunities

Despite all the progress made, there is still a long way to go before additive manufacturing becomes standard practice in the maintenance industry.

– We still see a lack of knowledge and understanding of what the technology can actually achieve. Many companies have not realised how they can integrate 3D printing into their maintenance processes.

At the same time, initiatives such as 3D-Action 2.0 are underway, providing support to small and medium-sized enterprises to explore and implement additive manufacturing.

– It often starts with an enthusiastic employee at the company, someone who has a printer at home in their garage and starts experimenting with solutions. When managers see the benefits, they quickly realise that it is a technology worth investing in, Marie-Louise says.

Underhållsmässan as a catalyst for change

RISE is an important partner for maintenance, and with the upcoming Swedish Maintenance Fair, Marie-Louise Bergholt sees great opportunities to highlight the role of additive manufacturing in the industry of the future.

– The fair is a fantastic platform for inspiring and spreading knowledge. We want to show how maintenance can go from being a necessary expense to becoming a strategic resource that drives sustainability and innovation.

With a combination of digitalisation, additive manufacturing and an increased focus on sustainable solutions, we are facing a new era in maintenance.

– The best thing we can do for the environment is to make our machines and components last as long as possible, with as little effort as possible. Additive manufacturing makes this possible, Marie-Louise concludes.

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