Evaluating the Logistics Performance of Printable Maritime Spare Parts Logistics through the Integration of Additive Manufacturing at Different Supply Chain Points
H. Singh (TU Delft - Civil Engineering & Geosciences)
E.B.H.J. van Hassel – Mentor (TU Delft - Mechanical Engineering)
M.W. Ludema – Graduation committee member (TU Delft - Technology, Policy and Management)
A. Napoleone – Graduation committee member (TU Delft - Mechanical Engineering)
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Abstract
When a vessel experiences an unexpected failure, the required spare parts are often not available onboard and must be delivered from shore. The current maritime spare parts supply chain depends on extensive logistics networks and large inventories. Although this system allows parts to eventually reach the vessel, it also creates several challenges. Deliveries can take considerable time, extending downtime and disrupting operations. International transport adds significant costs and emissions, while large inventories tie up capital and increase the chance that parts will become obsolete before being used.
Additive manufacturing, also known as three dimensional printing, offers a different approach by producing parts closer to where they are needed. Instead of shipping components across long distances, the design of a part can be sent digitally and printed onboard or at a nearby facility. Polymer based printing technologies have already proven reliable in maritime environments, showing that non critical parts can be produced effectively. Earlier studies have suggested that this approach could reduce costs, inventories, and transport emissions. However, most of this research focuses on individual cases and highlights specific advantages rather than comparing overall performance.
This thesis introduces a scenario based framework to examine how additive manufacturing affects logistics performance in the maritime spare parts supply chain. The study compares the current supply chain with three possible setups for additive manufacturing: onboard vessels, at ports, and in supplier warehouses. A polymer valve seat was chosen as the reference component because it represents a realistic, non critical part that can be printed with compact equipment. The analysis includes three delivery routes, Rotterdam to Hamburg, Singapore, and Dampier representing short, medium, and long distances. Each scenario is assessed using six indicators: lead time, logistics cost, inventory holding cost, spare parts availability, carbon emissions, and the investment required for additive manufacturing.
The results show that the impact of additive manufacturing depends on the location of production and the operational situation. Printing onboard brings the largest improvements, particularly for remote or long distance operations where waiting for deliveries would cause long downtime. Port based printing performs well on medium and long routes, while warehouse based printing mainly improves availability and stock management.
Overall, additive manufacturing can strengthen maritime spare parts logistics when applied thoughtfully and in a targeted way. It should be introduced gradually as a complementary capability that supports more resilient and sustainable operations.