How to manufacture obsolete parts with 3D printing
There is a fairly common problem in industry that often brings more projects to a standstill than one might think: a part breaks… and is no longer available. It could be a component for an old machine, a specific housing, a bracket, a part from a discontinued system, or a spare part that is impossible to source because the manufacturer stopped producing it years ago. And the worst part is that we’re often not even talking about a major critical part. Sometimes a small part can bring a production line, a machine or a piece of equipment to a complete standstill. Until recently, the options were quite limited: but industrial 3D printing is radically changing this situation. Today it is possible to reproduce many discontinued parts quickly, functionally and cost-effectively, even if no original drawings exist. And this is no longer an experimental process. More and more companies are using additive manufacturing to solve real-world problems relating to maintenance, operational continuity and industrial replacement. The real problem with discontinued parts When a part disappears from the market, the problem is not usually just the cost of the replacement. The real problem is everything it causes: downtime, delays, production stoppages, dependence on suppliers and loss of productivity. In many industrial settings, continuing to use older machinery remains entirely cost-effective. The problem arises when a small component is no longer manufactured and finding a replacement becomes an impossible task. This happens very frequently in: And this is where industrial 3D printing makes perfect sense. Because it allows parts to be manufactured on demand without the need for moulds, long production runs or reliance on the original manufacturer. 3D printing isn’t just for prototypes There are still companies that continue to associate 3D printing solely with models or visual prototypes. But the reality is very different. Current technologies allow for the manufacture of: Furthermore, thanks to technical materials and industrial technologies such as MJF, SLS or SLA, many of these parts can withstand: mechanical stress, temperature, vibration, wear and tear, or continuous use. That is why more and more companies are using additive manufacturing to solve industrial maintenance and replacement problems. How to manufacture a discontinued part using 3D printing One of the biggest misconceptions is thinking you need the original file for the part. Often, this isn’t necessary. There are now several ways to reproduce an old or discontinued part. 3D scanning If a physical part still exists, even if it is broken or worn, it can be scanned to generate a digital model. 3D scanning allows for the highly accurate capture of geometries, dimensions, complex shapes and technical details. This file can then be corrected and optimised before the new part is manufactured. Reverse engineering When original drawings are unavailable, the part can be digitally reconstructed using measurements and technical analysis. This is very common in: Furthermore, it often even allows for improvements to the original design. For example, reinforcing weak areas, reducing weight, optimising geometries or adapting the part to new requirements. Functional redesign In some cases, it is not necessary to copy the original part exactly. The important thing is that it fulfils the same function. Here, 3D printing offers a great deal of flexibility because it allows components to be redesigned, adapting them to the company’s actual use. And this often even improves performance compared to the original component. Key steps for manufacturing a discontinued part Although every project is different, the process usually follows these stages: 1. Part analysis The first step is to understand: Manufacturing a visual housing is not the same as manufacturing a part subjected to vibrations or temperature. 2. Digitisation or modelling Here, the 3D file is generated using: In many cases, this stage is used to correct defects or improve the original design. 3. Choice of technology and material One of the most important steps. The choice will depend on: strength, temperature, precision, finish, flexibility and end use. Choosing the wrong material can cause the part to fail quickly, even if it is perfectly manufactured. 4. Manufacturing and validation Once manufactured, the part is tested and validated in a real-world environment. Small iterations are often carried out to adjust tolerances or improve performance before manufacturing the final version. What types of parts are usually produced? Currently, discontinued parts are already being manufactured for a wide range of industrial applications. Some fairly common examples are: These are often relatively simple parts but essential for a machine to continue functioning. And this is where additive manufacturing allows the problem to be solved much more quickly than trying to source original spare parts. How to choose the right technology and material for printing spare parts Not all technologies are suitable for the same purpose. Choosing correctly depends on the actual use of the part and the environment in which it will operate. Technology Best for Advantages Limitations FDM Prototypes and basic functional parts Economical, fast and versatile Less precise finish SLA Detailed parts and fine finishes High visual precision Lower mechanical strength SLS Technical parts and complex geometries Very good strength Higher cost MJF Industrial production and functional parts Precision, repeatability and speed Requires industrial machinery Metal (DMLS/SLM) Demanding metal components Maximum strength High cost As for materials, some of the most commonly used today are: Material Typical application Characteristics ABS Enclosures and supports Impact-resistant PA12 Industrial parts Very good mechanical strength TPU Seals and flexible parts Elasticity and shock absorption ASA CF Exterior and automotive UV and weather resistance PAHT CF Demanding industries High thermal and mechanical strength Advantages and considerations before manufacturing a discontinued part 3D printing offers many advantages in this type of application, but there are also important aspects that should be assessed before manufacturing. Advantages Important considerations It is also important to bear in mind: Not all parts can be manufactured using any technology or material. That is why it is essential to analyse each case technically before manufacturing. It also allows for the improvement of parts that were constantly failing. Often, the original parts had problems: 3D printing not only allows the part to be copied. It also allows it to be improved. For example, by reinforcing certain areas, changing thicknesses, modifying geometries or using more resistant materials. This means that in some cases the new part works even better than the original. The great
