Industrial remanufacturing: why laser DED additive manufacturing is a game changer

What if the best part to produce were the one you don’t replace?

For a long time, when an industrial component reached the end of its life or had a damaged area, replacing it was the most obvious solution. Today, this approach is being called into question.

Faced with increasingly scarce resources, decarbonisation targets, supply chain pressures and competitiveness requirements, manufacturers are now looking for solutions that extend the service life of equipment while limiting its environmental impact.

In this context, remanufacturing is gradually establishing itself as a new industrial model.

Remanufacturing: a new approach to industrial performance

Remanufacturing is not simply about repairing a defective part. It aims to restore a component so that it regains a level of performance compatible with renewed industrial use.

This approach makes it possible to preserve high-value parts while reducing:

• Raw material consumption;
• Waste generation;
• Component replacement costs;
• Equipment downtime.

Beyond its environmental benefits, remanufacturing is becoming a real lever for competitiveness and resilience for manufacturers.

Laser DED additive manufacturing for component repair

Among the technologies making this development possible, laser Direct Energy Deposition (DED) processes, using powder or wire feedstock, now play a central role.

Their principle is simple: deposit material only where it is needed, with precise control of heat input and deposit geometry.

This level of control makes it possible in particular to:

• Repair damaged parts;
• Clad highly stressed areas;
• Restore worn components to their original dimensions;
• Improve surface properties in order to increase wear or corrosion resistance.

These processes are now mature enough to be integrated directly into demanding industrial environments, meeting the needs of sectors such as energy, rail, shipbuilding and automotive.

From one-off repair to a genuine industrial strategy

DED processes are no longer limited to one-off repair operations.

They pave the way for new industrial models that place the second life of components at the very heart of maintenance and production strategies.

This transition makes it possible to secure the availability of critical parts, reduce operating costs and limit dependence on supplies, while contributing to circular economy objectives.

The challenge is no longer just to manufacture high-performance parts, but also to preserve the value of those that already exist.

The European RESTORE project: accelerating the industrialisation of remanufacturing

This ambition lies at the heart of the European project RESTORE (Sustainable Remanufacturing solution with increased automation and recycled content in laser and plasma-based process), funded by the Horizon Europe programme under Grant Agreement No. 101138775.

The project aims to remove the main technical and industrial barriers in order to make remanufacturing fully industrialisable on a large scale.

The work focuses in particular on:

• The integration of recycled filler materials into additive manufacturing processes;
• The development of hybrid processes combining laser directed energy deposition (L-DED) and the Plasma Transferred Arc (PTA) process;
• The automation of repair operations;
• The optimisation of deposition paths;
• The complete digitalisation of the remanufacturing chain, from diagnosis to traceability of operations.

The objective is to offer higher-performance, more reproducible and more sustainable processes for applications on large components in the shipbuilding, rail, automotive and aerospace sectors.

Looking back at the PLI Conférences 2026

At the PLI Conférences 2026, held in Limoges, Jérôme Wursthorn, an expert at IREPA LASER, presented this development of laser DED processes applied to industrial remanufacturing.

His presentation highlighted feedback from industrial applications as well as the progress made within the RESTORE project.

Discussions with participants confirmed the growing interest of manufacturers and research players in these new sustainable manufacturing approaches, which combine industrial performance, cost control and a reduced environmental footprint.

IREPA LASER, driving innovation for a more sustainable industry

For more than 40 years, IREPA LASER has been supporting manufacturers in the development and industrialisation of innovative laser processes.

Thanks to its expertise in laser DED additive manufacturing, the team develops solutions tailored to the repair, cladding and remanufacturing of industrial components, while contributing to the major European projects shaping the industry of tomorrow.

Because industrial performance is no longer just about manufacturing better, but also about preserving, repairing and restoring value to what already exists, IREPA LASER continues its commitment to a more competitive, sustainable and responsible industry.

Find out more

Discover the European RESTORE project

IREPA LASER is a partner in the RESTORE project (Sustainable Remanufacturing solution with increased automation and recycled content in laser and plasma-based process), funded by the Horizon Europe programme (Grant Agreement No. 101138775).

This project aims to make remanufacturing a sustainable, high-performance and fully industrialisable solution through additive manufacturing processes, automation and digital tools.

>> Find out more about the RESTORE project

Do you have a repair or remanufacturing project?

Would you like to extend the service life of your components, optimise your maintenance processes or integrate laser DED additive manufacturing into your industrial strategy?

IREPA LASER’s experts support you in developing tailor-made solutions, from the feasibility study through to the industrialisation of your processes.

>> Contact our experts to discuss your project