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DigiRepair: Digital Adoption and Additive Manufacturing Innovation for Next-Generation Aerospace and Power Generation Repair

Projects/Open Innovation
11 hours ago
2 min read

Industrial Need

Maintenance Repair and Overhaul (MRO) industries - specifically UK aerospace and power generation MRO - are continuing to scrap high-value components due to wear or damage that cannot be economically repaired using conventional methods, driving material waste and long supply chain lead times. Part of the reason is that SME repair providers rely on overly manual, spreadsheet-based workflows with limited digital traceability, constraining quality assurance, capacity growth, and effective adoption of Industry 4.0 practices.



Project innovation


DigiRepair will address these twin challenges by combining advanced additive manufacturing (AM) repair processes with an integrated digital thread tailored to SME needs -- resulting in significant SME resource efficiency and industrial MRO outputs.


The project will demonstrate how AM-based repair methods (high pressure cold spray (HPCS) and laser directed energy deposition (DED) repair routes), underpinned by end-to-end digital workflow management and Quality Information Framework (QIF) compliant data structures, can achieve significant cost, energy, and material savings.


Three core technical developments will be delivered:


  • High-Pressure Cold-Spray (HPCS) repair workflows for aerospace components at ACLAS Technics, supported by NMIS, will be defined and evidenced, turning today's scrap into repairable assets and generating the data necessary to support future certification.

  • Laser Additive Solutions' (LAS) existing laser DED blade repair processes will be digitally enabled, capturing machine, scan and inspection data to improve repeatability, reduce bottlenecks and enhance traceability.

  • Authentise's digital workflow platform will be enhanced for SME MRO environments to replace spreadsheet-based planning with interoperable, QIF-aware digital execution and data management.


Impact


  • Economic: Combined consortium revenue growth of £1.2M-£2.5M within three years, creating 10-15 high-skilled jobs (AM process engineers, quality assurance specialists). Customer benefits for aerospace and power generation MRO; targeting 40-60% cost savings, 70-85% lead time reductions to drive demand growth.

  • Environmental: Quantified sustainability benefits of 50,000-80,000 kg CO2e/year avoided emissions post-project through eliminated scrap (8,100-13,500 kg CO2e/year), reduced rework (3,000-4,000 kg CO2e/year), and optimised energy consumption. Project addresses £500M annual global scrap-avoidance opportunity across 112,000 component removals.

  • Wider Benefit: Validated QIF-compliant digital frameworks provide replicable adoption pathway for UK SME manufacturing base across medical devices, nuclear, and oil/gas sectors. NMIS dissemination through Made Smarter networks accelerates sector-wide adoption, with potential to reduce Beyond Economical Repair rates from 16% to 5% globally, supporting UK Industrial Strategy clean growth objectives and reducing strategic dependence on volatile international OEM supply chains. 


👉 Find out what other projects we are working on here.

 
 
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