A Sustainable Business Model for Aircraft Logistic Support Powered by Additive Manufacturing

This thesis explores the integration of Additive Manufacturing (AM) in the logistics and supply chain of Leonardo S.p.A.’s Aircraft Division, with a particular focus on developing a business model for the production of polymer parts. Leonardo S.p.A. is a global leader in Aerospace, Defense, and Security, renowned for its advanced technological solutions and commitment to quality and sustainability. The company offers a diverse range of products, including helicopters, aircraft, unmanned aerial vehicles, and electronic systems, serving both military and civil markets worldwide. Notably, Leonardo already employs AM-produced parts in its operational vehicles, underscoring the company’s commitment to innovative manufacturing methods. Aimed at enhancing efficiency in the provision of spare parts and Ground Support Equipment (GSE), this study highlights AM's potential to reduce lead times, enable on-demand production, and improve flexibility within manufacturing processes. Emphasis is placed on Fused Filament Fabrication (FFF) and Powder Bed Fusion (PBF) technologies as primary methods for polymer and metal parts production, respectively. Prior to proposing AM as a transformative solution, an in-depth analysis of the company’s existing operational framework was conducted to ensure alignment with Leonardo's strategic and logistical practices. This preparatory study provided essential insights into how such a disruptive innovation could be integrated effectively within current systems. The proposed business model leverages a performance-based approach, aligning production capabilities with client demand while ensuring cost predictability. An economic analysis demonstrates that, under specific assumptions regarding demand levels, operational scale, and resource allocation, the model is profitable. The study finds that the AM-based model offers competitive advantages over traditional manufacturing by reducing the need for extensive inventories and capital investment in tooling, particularly in low-to-moderate demand scenarios. Additionally, the model’s flexibility and adaptability present long-term cost savings by mitigating risks associated with obsolescence and storage, thereby supporting a scalable, financially sustainable solution. These findings underscore AM's strategic role in reducing obsolescence risks, supporting sustainability goals in line with the European Green Deal, and enhancing supply chain resilience in the Aerospace and Defense sectors. Ultimately, this thesis provides insights into the economic, operational, and environmental advantages of AM for polymer and metal parts production.