3D printed spare parts

Due to increasing product diversity, companies with long-term capital goods are increasingly lamenting the high storage costs for spare parts. The problem: availability is becoming more critical, especially for old spare parts, which significantly increases the risk of breakdown losses. This is opening up a new, but demanding field of application for additive manufacturing. Since most spare parts have been conventionally manufactured and have often passed through an approval process, it is generally not possible to create a copy of this component in 3D printing. Instead, this requires a complex adjustment process in order to transform a conventionally manufactured spare part into a spare part for additive manufacturing, which can be produced “on demand” if required.

We identified this challenge early on and, with “SPOD” (spare parts on demand), developed a multi-stage process that lets us guide you into a new era of spare part production.

Take advantage of our service for 3D printed spare parts. Test us out. Send your inquiry and we will promptly reply to arrange a non-binding consultation.



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Our process


Why FIT?


  • 5 % - the answer to the question of how many spare parts from your warehouse are suitable for SPOD.
  • 18 months - the average duration of a SPOD project.
  • 30 % - the average reduction in the total cost of ownership (TCO) for the relevant spare part by using SPOD (compared to conventional production).
  • 75 % - the amount by which the response time is likely to improve with SPOD, with the additive manufacturing of spare parts rather than using conventional technologies.


Application example

As the manufacturer of the left sandbox housing, part of the brake system, ceased production, Deutsche Bahn risked a train failure. Since the component was manufactured as grey cast iron, no 3D printed copy could be produced. As a result, we re-engineered the component and then additively manufactured it from titanium using EBM. The component has passed the tests performed to date. If the worst were to happen, Deutsche Bahn can now quickly respond to a failure.

Application example
Spare parts analysis


Spare parts analysis

In the first step of the SPOD process, we jointly select the spare parts from your stock, whose availability is critical, whose probability of failure is classified as high, and whose costs of failure are significant. We then examine these “critical” spare parts to confirm whether additive manufacturing is possible. For the spare parts that are ultimately selected, we jointly define the relevant indicators and formulate corresponding target values.


SPOD contract

The SPOD contract defines the framework of our cooperation. It contains your requirements for the production of the relevant spare parts where this is necessary. It specifies your and our rights and obligations, defines the respective responsibilities during the project phase as well as the conditions and the schedule for the project and any additional cooperation. It is jointly developed in close collaboration and represents the foundation of our cooperation.
SPOD contract
Feasibility study


Feasibility study

The aim of the feasibility study is to find the best path for the additive manufacturing of your spare parts. There is often more than one way to reach the goal. Many different options are available for manufacturing a component using the additive or conventional technology. The best path for you therefore needs to be considered from cost and risk perspectives. Initial planned costs for the manufacturing are determined for this solution to enable clear budgeting.


Design and component engineering

A 3D record of the SPOD spare parts generally does not exist, only drawings or an original. No problem. In the 4th phase of the SPOD process, we scan your component or design a 3D model, which we use as a basis for adapting the component for the selected production process and save as a printable record. We use tests, simulations and iteration loops to ensure that the component fully retains its original function.
Design and component engineering
Spare part production


Spare part production

Subject to any necessary approval, we then immediately start manufacturing your component if required. As the key parameters have already been defined in the previous phases of the SPOD process, speedy production, finishing, and the necessary quality control are ensured.

“With more than 50 systems for additive manufacturing, we can always guarantee that your spare parts will be produced.”

Alexander Bonke, Managing Director FIT Production GmbH



Fulfillment

Besides production, we also offer additional upstream and downstream services related to the topic of “3D printed spare parts”. Upon request, we can provide a customizable online portal, which lets you control and execute your entire SPOD order management process. We naturally also organize the global shipping of your spare parts, take over any assembly activities, storage or the timely picking of various spare parts.
Fulfillment

Additive manufacturing

Laser Meting (LM)
Electron Beam Melting (EBM)
Wire Arc Additive Manufacturing (WAAM)
Full-color PolyJet
Selective Laser Sintering (SLS)
Stereolithography (SLA)
PolyJet (FLT)
Binder Jetting (Drop on Powder)
Gel Dispensing Printing (GDP)

Conventional manufacturing

Injection molding
More info
Vacuum casting
More info
Polyamide casting
More info
RIM
More info
Milling
More info
Laminating
More info
Tool manufacturing
More info

Finishing techniques

Metal coating
Heat treatment
Infiltrating
Blasting
Painting
Polishing
Barrel finishing
Smoothing
Finishing

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FIT AG
Am Grohberg 1
92331 Lupburg
Germany

© Copyright • 17.12.2018 • FIT AG • All Rights reserved