Producing spare parts close to where they are needed can reduce dependence on stored inventory and long-distance deliveries. This article examines a 2025 collaboration between Daimler Buses, 3D Systems, Oqton and Wibu-Systems, and the technical, licensing and economic conditions behind remote production.
Potential applications for additive spare-part production span aerospace, defence, automotive, rail, energy and maritime industries. The business case depends on the part, demand and qualification requirements.
An earlier Strategy& interview with Professor Claus Emmelmann projected a 10% share of the spare-parts market within five years. This was a forward-looking opinion in that interview, not a measured adoption rate or a new five-year forecast beginning in 2025.
In the automotive industry in particular, three key arguments are driving the use of AM for spare parts management: cost efficiency for low-demand parts, supply chain optimization as well as restoration of (vintage) vehicles.
Despite these benefits of using AM, the adoption of spare parts management solutions remains limited due to several challenges the technology presents: the access to the digital design data – often linked to IP and legal issues, material considerations, as well as the business case.
Additive Manufacturing has often been criticized for the fact that products have not been designed for the technology in mind, but rather for manufacturing processes like injection molding, CNC machining, or casting.
As such, there may be no original digital data available which means that the engineer will have to identify the design files for the parts needed first, before finding a solution to streamline the workflow, from part design to manufacturing.
Additionally, we need to acknowledge that there are still many materials that deliver reduced mechanical properties when they are printed, 3D printers that can only process one material or even many automotive-grade alloys and composites used in conventional manufacturing are difficult to 3D print.
On top of that, we still need to assess the viability of AM on a case-by-case basis as the technology cost is not often compatible with all scenarios.
As is the case with many challenges faced across other verticals, addressing these technical issues cannot be the sole responsibility of one company; that’s what we learn through the example of Daimler Buses.
Addressing each challenge one collaboration at a time
In the short list of automotive manufacturers who are already betting on AM for spare parts management, one that is leading the way on the road is Daimler Truck | Daimler Buses.
Daimler Buses uses additive manufacturing in after-sales support, including parts with low or irregular demand. The availability of a design for 3D printing must be distinguished from the approval and commercial availability of a finished replacement part.
The collaboration announced on 23 January 2025 combines Daimler Buses’ parts expertise, 3D Systems’ equipment, Oqton’s 3DXpert software and Wibu-Systems’ digital rights management. It follows earlier work on Daimler Buses’ 3D-printed parts shop.
This time, to facilitate remote spare part printing, the three companies join forces to enable Daimler Buses to deliver enhanced service capabilities to its certified additive manufacturing (AM) partners while protecting its valuable intellectual property (IP) and competitive position.
In practice, how 3D Systems’ solutions help Daimler Buses overcome its technical challenges
3D Systems supplies hardware, software, materials and services. This case centres on a specific workflow rather than unrestricted access to every system and material in its portfolio.
While the company’s solutions serve advanced applications in healthcare and industrial markets, the industry still needs clarity on which solution fits which application.
In this specific case, bus/motorcoach companies or service bureaus that join Daimler Buses’ network of 3D printing certified partners can now purchase a license for 3DXpert through Daimler Buses’ Omniplus 3D-Printing License eShop.
In the licensed workflow described by the partners, 3DXpert prepares authorised design files for printing, while digital rights management controls decryption and the permitted quantity. This does not remove the need for the design owner’s permission or for part and process qualification.
Roy Sterenthal, Vice President, Industrial Additive, Oqton commented, “Our 3DXpert software is renowned as an all-in-one solution to streamline the additive manufacturing production workflow. By combining this capability with Wibu-Systems’ robust digital rights management solution, we’re helping Daimler Buses safeguard its intellectual property while accelerating its supply chain. I’m pleased that we can be part of this innovative solution to produce on-demand critical components, reduce reliance on global logistics, and ultimately return vehicles to service faster than ever.”
At the January 2025 announcement, the initial workflow was designed around the SLS 380. Its powder-management equipment supports material preparation and reuse. A printer’s broader materials portfolio does not mean that every material is approved for every Daimler spare part.
“By commercializing this digital service solution, Daimler Buses is not only adopting a new technology; they’re fundamentally reshaping the supply chain for greater resilience and efficiency,” said Jaime Garcia, Additive Solutions Manager – Automotive and Commercial Transportation, 3D Systems. “Our SLS 380 is a high throughput additive manufacturing solution with unprecedented levels of throughput, consistency, performance, and yield. I’m pleased that this is the first 3D Systems technology to be integrated into Daimler Buses’ workflow.”
The partners described compatibility with additional polymer and metal systems as a future objective. The announcement did not establish that all those systems were already supported.
Then vs Now
Missing components such as inserts or covers can keep a vehicle out of service. Producing an approved replacement through a nearby certified partner can shorten the supply route, but the actual lead time includes licensing, preparation, printing, finishing and inspection.
In their January 2025 announcement, the partners reported a potential reduction of up to 75% in the time to receive parts, covering applications such as pins, covers and inserts. This is a benefit stated by the project partners, not a guaranteed reduction for every order. Any savings from reduced vehicle downtime depend on the particular maintenance case.
This content has been created in collaboration with 3D Systems.
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