Evaluation of Additive Manufacturing Methods for Obsolete Components : A Comparison of WAAM, LPBF and Casting

Sammanfattning

This thesis investigates alternative manufacturing methods for an obsolete spare part component previously produced by casting, within the context of low-volume production in the defense industry. The study compares casting, Wire Arc Additive Manufacturing (WAAM) and Laser Powder Bed Fusion (LPBF) with respect to cost, lead time, manufacturability and design flexibility. A qualitative case study approach was applied, combining a background study, component redesign and manufacturing method evaluation. WAAM was further assessed through a series of experiments to evaluate process parameters and buildability, while LPBF was evaluated based on design considerations and expert consultation. The results indicate that WAAM enables cost-effective, in-house production with short lead times and sufficient functional performance, although post-processing is required. LPBF offers improved geometric accuracy, surface quality and potential weight reduction, but is associated with higher costs and reliance on external suppliers. Casting was found to be technically feasible but economically unsuitable for very low production volumes due to tooling costs and long lead times. The study concludes that WAAM is the most suitable method when cost, availability and lead time are critical, while LPBF is a viable alternative when performance and surface quality are prioritized.