Shared Additive Manufacturing Network for Metal Remanufacturing: Cost-aware Hub Distribution and Order Allocation

Abstract With an increasing emphasis on sustainability, remanufacturing has become essential in conserving resources and extending product lifecycles within the manufacturing sector. Additive manufacturing (AM) offers significant advantages for metal remanufacturing across industries such as aerospace, defense, and marine by providing flexible, precise repairs that surpass traditional methods. However, the high capital costs associated with in-house AM facilities pose substantial challenges for many small- and medium-sized enterprises (SMEs). Recent research highlights AM’s potential within a distributed manufacturing model, facilitating shared manufacturing capacity that allows multiple clients to access AM-based repair and restoration services without the financial burden of maintaining in-house facilities. Despite these benefits, research on designing and optimizing shared AM networks at a systems level remains limited. In this study, we develop a mathematical model to optimize AM hub locations and order allocation, considering variable repair orders from geographically distributed locations and associated transportation logistics. A case study of AM hubs serving the metal part remanufacturing needs of machine shops in the state of North Carolina in the U.S. is conducted to assess the effectiveness of the proposed method. The results demonstrate that strategically located AM hubs significantly enhance cost-efficiency within the shared network, providing SMEs affordable access to advanced AM resources and promoting a shift towards a circular economy.