Industrial obsolescence as a cross-industry threat

Every day, production lines around the world risk grinding to a halt because of the unavailability of a single component. This is no longer an exceptional event, but a systemic vulnerability affecting highly regulated and mission-critical industries. According to PandCT – All about Supply Chain 4.0, the manufacturing sector loses more than $50 billion annually due to unplanned downtime, with hourly costs skyrocketing whenever a production line unexpectedly stops.

The causes are manifold: aging equipment, discontinued spare parts, loss of technical documentation, or unreliable suppliers. In industries such as pharma and aerospace, where compliance and reliability are non-negotiable, industrial obsolescence is no longer a remote possibility but a critical risk leading to extended downtime and significant value loss.

Costs of downtime

When a plant stops due to the unavailability of a critical component, the damage extends far beyond lost production. Unplanned downtime creates a ripple effect of hidden costs: idle personnel, contractual penalties, delivery delays, complex restarts, and reputational damage with customers.

A recent analysis by IDS-INDATA projects that by 2025, losses linked to unplanned downtime will exceed £80 billion in the UK and Europe alone, with particularly severe impacts across manufacturing, energy, and aerospace. These figures clearly demonstrate that obsolescence is not just a maintenance issue, but a systemic risk capable of undermining competitiveness and profitability.

A fragile supply chain

The traditional model, based on external suppliers and centralized physical inventories, is showing its weaknesses. Global supply chains, already under pressure from the pandemic, geopolitical tensions, and energy market volatility, are too slow and inflexible to respond effectively to emergencies or sudden demand. The World Economic Forum, in its Global Risks Report 2024, ranks supply chain fragility among the top five systemic global risks, highlighting how the failure of a single link can disrupt entire production ecosystems.

The AMPOWER Report 2024 confirms this trend, forecasting 13.9% annual growth in on-demand spare parts production by 2028. This indicates a structural shift: the industry is moving away from static warehouses filled with costly, often obsolete stock, toward digital warehouses that are more distributed, agile, and resilient.

From digital warehouse to on-demand production

In this context, industrial additive manufacturing emerges as the technological lever capable of turning obsolescence into opportunity. By building digital spare parts libraries, companies can rely on a constantly updated virtual inventory, activating on-demand production only when needed. Reverse engineering enables reconstruction of components even without original drawings, while advanced certified materials ensure performance and compliance with the highest industry standards.

This transition eliminates the need for costly molds and tooling, drastically reduces lead times, and allows rapid adaptation of geometries to new operational requirements. Moreover, the digitalization of spare parts introduces a new level of traceability and quality control, reinforcing trust in additive manufacturing even in the most regulated sectors, from aerospace to pharmaceuticals.

Measurable benefits

The impact of on-demand production with digital spare parts is tangible, delivering measurable business outcomes:

• Lead times reduced by up to 70–80% compared to traditional supply models, enabling faster response in critical scenarios.

• Built-in traceability and compliance, thanks to certified materials and digitally validated processes, simplifying audits and inspections.

• Optimized inventory management, with drastic reduction of obsolete stock and slow movers, freeing up tied capital.

• Greater supply chain resilience, shifting from a reactive to a proactive model, ensuring business continuity even in uncertain global contexts.

These benefits demonstrate that the digitalization of spare parts is not merely a tactical solution to manage industrial obsolescence, but a true operational paradigm shift, directly impacting long-term competitiveness.

Case study

A major railway operator avoided downtime costs estimated in the tens of thousands of euros per day by reproducing, via additive manufacturing, a component that was no longer available on the market. Instead of waiting months for delivery, the part was redesigned and produced within days, ensuring full compliance and continuous operations.

Discover more real-world examples in the Roboze white paper: download it from the dedicated landing page to learn how to turn obsolescence into competitive advantage.

Governing obsolescence with Roboze

Industrial obsolescence is not a condition to endure but a process to govern. By digitalizing spare parts, companies can reduce dependency on third-party suppliers, increase responsiveness, and transform the supply chain into a strategic asset. With high-performance materials, advanced engineering know-how, and robust digital platforms, Roboze is the ideal partner to lead enterprises toward a more resilient, secure, and competitive future in additive manufacturing.

Contact our experts today for a tailored consultation.