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Although the adoption of metal additive manufacturing (AM) for production has continuously grown, in-house access to production grade metal AM systems for small and medium enterprises (SMEs) is a major challenge due to costs of acquiring metal AM systems, specifically powder bed fusion AM. On the other hand, AM technology in directed energy deposition (DED) has been evolving in both: processing capabilities and adaptable configuration for integration within existing traditional machines that are available in most SME manufacturing facilities, e.g. computer numerical control (CNC) machining centers. Integrating DED with conventional processes such as machining and grinding into Hybrid AM is well suited for remanufacturing of metal parts. The paper aims to discuss these issues.

Classical facility location models are employed to understand the effects of SMEs adopting DED systems to offer remanufacturing services. This study identifies strategically located counties in the USA to advance hybrid AM for reverse logistics using North American Industry Classification System (NAICS) data on geographical data, demand, fixed and transportation costs. A case study is also implemented to explore its implications on remanufacturing of high-value parts on the reverse logistics supply chain using an aerospace part and NAICS data on aircraft maintenance, repair and overhaul facilities.

The results identify the candidate counties, their allocations, allocated demand and total costs. Offering AM remanufacturing services to traditional manufacturers decreases costs for SMEs in the supply chain by minimizing expensive new part replacement. The hubs also benefit from hybrid AM to repair their own parts and tools.

This research provides a unique analysis on reverse logistics through hybrid AM focused on remanufacturing rather than manufacturing. Facility location using real data is used to obtain results and offers insights into integrating AM for often overlooked aspect of remanufacturing. The study shows that SMEs can participate in the evolving AM economy through remanufacturing services using significantly lower investment costs.

This paper aims to investigate the extent to which traditional manufacturers are equipped and interested in participating in a hybrid manufacturing system which integrates traditional processes such as machining and grinding with additive manufacturing (AM) processes.

A survey was conducted among traditional metal manufacturers to collect data and evaluate the ability of these manufacturers to provide hybrid – AM post-processing services in addition to their standard product offering (e.g. mass production).

The original equipment manufacturers (OEMs) surveyed have machine availability and an interest in adopting hybrid manufacturing to additionally offer post-processing services. Low volume parts which would be suitable for hybrid manufacturing are generally more profitable. Access to metal AM, process engineering time, tooling requirements and the need for quality control tools were equally identified as the major challenges for OEM participation in this evolving supply chain.

OEMs can use this research to determine if hybrid manufacturing is a possible fit for their industry using existing machine tools.

Survey data offer an unique insight into the readiness of metal manufacturers who play an integral role in the evolving hybrid supply chain ecosystem required for post-processing of AM metal parts. This study also suggests that establishing metal AM centers around OEMs as a shared resource to produce near-net AM parts would be beneficial.