Powder-Logistics Concept for Future LPBF High-Volume Shop Developing a scalable powder-logistics concept for serial LPBF production

Abstract

Following the increasing use of additive manufacturing in aerospace production, Laser Powder Bed Fusion has become an important technology for producing complex and lightweight metal components. However, scaling LPBF from a low-volume demonstration environment to high- volume serial production creates new requirements for powder-logistics. Metal powder must be handled safely, traceably and efficiently, while risks related to manual handling, contamination, ergonomics and tied-up capital need to be controlled. This study investigates a company within the aerospace industry that is preparing a future high- volume LPBF production facility. The current powder-logistics setup is mainly designed for low-volume development and learning and is therefore not suitable for the expected increase in production volume, material movements and parallel powder flows. Therefore, this study aims to support the company by developing and evaluating a powder-logistics concept that enables safe, traceable, cost-efficient and scalable operations. Through observations, interviews, internal data, workshops, Material Flow Mapping and Systematic Layout Planning, several limiting factors were identified and analyzed. These included manual handling, unclear storage logic, high handling frequency, traceability requirements, operational risks and the need for future scalability. To address these factors, a final powder-logistics concept is proposed. The concept includes a structured cell-based layout, larger powder units, defined storage and filling zones, improved identification systems, lifting support and is automation-ready. By implementing the proposed concept, the company can reduce handling complexity, improve traceability and operator safety, and create a scalable structure that can be multiplied as production volume increases.