Designing Reverse Logistics Networks for Metal Remanufacturing with Cloud-Based Additive Manufacturing Systems

As the circular economy becomes increasingly important in manufacturing, demand is rising for technologies that improve repair, restoration, and remanufacturing processes. Additive manufacturing (AM) shows great potential in metal remanufacturing and reverse logistics for industries like defense, aerospace, and automotive, due to its flexible processing and distributed manufacturing capabilities. While research has focused on metal AM’s repair precision and efficiency, few studies have examined its impact at the supply chain level. This study fills that gap by investigating cloud-based AM services (CA-RMfg), which support reverse logistics in metal remanufacturing while lowering capital and technical barriers for small and medium enterprises (SMEs). In this study, we developed a bi-objective reverse logistics model within a CA-RMfg framework, linking key facilities and managing network variability. A real-world case study involving aircraft engine repair providers in Texas, identified through NAICS-SIC codes, demonstrates the model’s effectiveness. Findings reveal that while a larger distribution of AM hubs can reduce wait times, it may raise unit repair costs for SMEs due to facility underuse. However, optimized AM hub placements significantly lower these costs for SMEs, achieving up to double or triple the reductions compared to in-house facilities.