Feasibility assessment of manufacturer-controlled spare parts manufacturing using AM technology: A case-study in vacuum cleaners

Abstract

This graduation project delves into the use of Additive Manufacturing (AM) to produce spare parts through a case study of vacuum cleaners. Waste from Electrical and Electronic Equipment (WEEE), including products like vacuum cleaners, challenges the European Union’s (EU) sustainability goals. In 2020 alone, the EU collected an estimated 12.4 million tonnes, representing 10.5 kilograms per person. To address this issue, the “Right to Repair” was adopted. This initiative aims to promote repair as a strategy to slow down WEEE by mandating companies offer 10 years of post-warranty spare parts availability and 15 days of lead time. This mandate challenges companies’ responsiveness due to the extended period of support and limited lead time. Am provides an opportunity to fulfil these requirements while also offering additional benefits such as the digitalisation of the supply chain and reducing the environmental impact of the company’s operations.
The main research goal of the project is the development of a framework for evaluating the suitability of components within a product to be AM printed as spare parts. The framework is established through a literature review across three primary research areas: Priority components (identifying key components for repair activities), Printability (assessing component suitability for AM printing) and Spare Part Suitability (evaluating components’ suitability for supply chain considerations). The proposed framework, encompassing three primary steps, narrows down the components from a complex product to focus on those that present greater AM eligibility. This, in turn, guides the company’s effort in designing, testing and making these eligible parts commercially available.
Step 1. Cut-off criterion: Aims to exclude components defined as not suitable for AM printing, such as standardized elements and electronics.
Step 2. Eligibility Evaluation: Assess components eligibility for AM spare parts printing within the research areas.
Step 3. Component Selection: A top-down approach is employed. It begins with the selection of repair priority components, from his group those deemed AM printable are identified, and finally, components aligned with supply chain suitability are selected.
Takeaways from the conducted research also involve the insights gathered from the conducted framework validation, which involved two Philips vacuum cleaners and the use of Selective Laser Sintering (SLS) for the printing of spare parts. Lastly, this thesis establishes a foundation for the exploration of AM potential in the realm of spare parts manufacturing and future product design.