Leveraging Digital Design and Manufacturing Processes for In-House Spare Parts Production A Living Lab Experiment

This study explores the implementation of digital design and manufacturing technologies for aftermarket spare parts production in the fitness equipment restoration industry. Through a two-year action research project within a living lab setting, we assess the feasibility, profitability, and operational impact of establishing a digital manufacturing cell in a company without prior experience in this domain. The research employs a mixed-methods approach, combining quantitative analysis of production data with qualitative case studies of specific new products. Key findings reveal significant cost savings, reduced lead times, and enhanced supply chain resilience through the adoption of additive manufacturing (AM) and CNC technologies. Within the first year, the manufacturing cell produced over 5,000 parts, with 17% addressing urgent demands, demonstrating the ability to meet variable and time-sensitive production needs. However, challenges such as the continuous need for reverse engineering skills and managing demand fluctuations were identified. This paper advances understanding by providing a detailed, empirical framework for SME adoption of digital manufacturing technologies, addressing gaps in the literature related to practical implementation and scalability. Furthermore, the integration of intellectual property considerations and sustainability practices enriches the study’s relevance. By offering actionable insights and a replicable framework, the research contributes to the economic and operational viability of SMEs transitioning to digital manufacturing, particularly those with limited resources and predominantly non-graduate workforces.