An analysis of technical and economic aspects of digital spare parts on variating materials in powder bed fusion of metals using a laser beam (PBF‐LB/M)

Conventional supply chains depend on spare part inventories for rapid failure response. Metal additive manufacturing enables decentralized, on‐demand production, reducing inventory needs. Current research focuses on redesigning spare parts using failure data. Key aspects include lightweight design through generative topology optimization, material substitution, and cost analysis to improve efficiency. Generative design enhances performance while reducing material use and production costs, supporting sustainability. This is especially relevant in industries where weight and material savings improve performance and reduce expenses. This study presents an integrated approach combining material selection, bionic design, and cost estimation in metal additive manufacturing to evaluate decentralized spare part reproduction. Findings show that generative design enables fast, cost‐effective, and sustainable improvements, supporting operational efficiency and environmental goals.