A48 / Article

Repair ROI Formula for LMD Repair

The repair ROI screen compares replacement path cost with repair path cost by combining replacement price, downtime, repair estimate, repair extras, lead-time difference and an uncertainty buffer for the repair route.

Industrial metal component prepared for repair or rebuild

Answer at the top

One-sentence buyer answer.

Use it when

When to use it.

The page is being used to structure an RFQ, supplier check or documentation question.
The main leverage sits in stronger input quality, not in a fast price with thin context.
NDA, drawing release or acceptance logic need early clarity.

Avoid it when

When not to use it.

A quick price is being requested with no technical input.
Several suppliers are being compared while scope and acceptance remain undefined.
Confidentiality is only raised after sensitive files have already been shared.

Decision table

What usually decides the route.

Decision table with decision point, good sign and escalation signal.
Decision point	Good sign	Escalate or avoid
Input quality	Drawings, photos, material and the target function are available.	The request stays generic and data-light.
Comparability	Scope, finishing, inspection and documentation are requested consistently.	Quotes are being compared only on a single price line.
Confidentiality	NDA and file-sharing rules are clear early.	IP protection is only raised late in the process.
Release logic	Acceptance criteria and documentation needs are defined.	PO or release is moving forward without a clear evidence base.

Readable summary:

A useful RFQ includes drawings or photos, material, target function, timing, finish and inspection needs.
Escalate when the request is generic, data-light or compares suppliers only on one price line.
Clarify NDA and file-sharing expectations early.

Industrial example

Public proof with similar logic.

CS10 - Nobufil Extrusion Screw Repair: Short-Lead-Time LMD Rebuild of a Cracked Stub Shaft

How Exafuse repaired a cracked Nobufil extrusion screw shaft with a targeted DED/LMD route when no replacement screw was immediately available.

Open related case study

Material and quality

What has to travel with the decision.

Material

Even in procurement, the material route should stay tied to function and substrate.
If substitution is possible, it needs a clear approval rule.

Quality

A good RFQ names inspection, documentation and the delivery condition.
Supplier qualification is stronger when deviation handling and release logic are asked explicitly.

Inspection and validation

Checklist before request or release.

Service type and target of the job
Drawing, CAD or photos
Material or substrate assumption
Inspection and documentation package
NDA, timing and delivery terms

Repair decisions are rarely about repair price alone. The real comparison is the full path.

The short answer

The Exafuse repair ROI screen compares replacement path cost against repair path cost. Replacement path cost is replacement price plus downtime during replacement lead time. Repair path cost is repair estimate plus finishing and inspection extras, multiplied by an uncertainty buffer, plus downtime during repair lead time.

The formula

Replacement path = replacement cost + (downtime cost per day x replacement lead-time days)
Repair path = (repair base estimate + repair extras) x (1 + uncertainty buffer) + (downtime cost per day x repair lead-time days)
ROI signal = replacement path - repair path

If the number is positive, repair may be commercially worth investigating. If the number is negative, replacement may be competitive or safer.

Break-even downtime

The tool also shows the downtime cost per day at which the repair path starts to make commercial sense, if repair has a lead-time advantage. If repair is not faster, the break-even downtime field makes that visible instead of hiding the timing assumption.

Why the uncertainty buffer exists

Repair work carries technical uncertainty: hidden damage, extra machining, intake findings or validation needs can move the scope. The uncertainty buffer makes the screen more honest by avoiding false precision.

What this screen is good for

It is good for maintenance and procurement teams that need a first business-case discussion before sending a part for technical review.

What this screen is not

It is not proof that repair is feasible, lower risk or technically approved. It is only the commercial side of the first question.

Inputs that matter most

Replacement price, lead time, downtime cost, repair estimate, finishing/inspection extras and the chosen uncertainty buffer all change the result materially.

Useful next pages

Use the Repair ROI, A01: repair vs replace, Estimator, RFQ builder and Repair and modification together when a repair economics is under review.

Buyer questions

Exact buyer questions that usually lead here.

What belongs in a good RFQ at minimum?

Service type, geometry, material, target zone, timing and acceptance logic are the usable core.

How should quotes actually be compared?

Not only on a deposition price, but on scope, finishing, inspection, documentation and the assumptions underneath them.

When should NDA be raised?

As early as possible, ideally before sensitive drawings or internal information are shared.

When should I consider LMD repair instead of replacement?

Consider repair when the part still has a sound base structure and the failure is concentrated in a limited zone such as a worn edge, seat, tooth, bore, or shaft area.

Recommended next steps

Tools, proof and related pages in one block.

Free tools

Compare repair with replacement Screen base cost drivers Find the right route

Related proof and guides

PageRepair service Case studyCS10: Nobufil Extrusion Screw Repair: Short-Lead-Time LMD Rebuild of a Cracked Stub Shaft Case studyCS12: 24-Hour Inconel 718 Coating Repair for an Undersized Spindle FAQFAQ03: Repair vs Replace FAQ: Economics, Risk, and Maintenance Scheduling ArticleA01: Repair vs Replace for High-Value Metal Parts: A Decision Framework ArticleA05: Repair ROI Model: How to Quantify Downtime, Machining, and Validation Costs

Recommended next steps

Move from article to decision.

Continue with the closest service page, proof example, FAQ or feasibility request.

Repair assessment

Send photos and dimensions for repair review

Best for worn, damaged or undersized high-value parts where replacement cost, lead time or downtime is painful.

Request repair assessment

Free tools

Choose the next tool.

Use the relevant screen before sending data or requesting a call.

Business caseCompare repair with replacement

Useful when replacement cost, lead time or downtime drives the decision.

Cost screenScreen base cost drivers

Helps frame dimensions, material family, quantity and process assumptions early.

Free toolFind the right route

For cases where the problem is clear but the service, process or next step is still open.

Direct contactRequest a Teams or phone call

Best for NDA questions, unclear data or urgent cases that need a short conversation first.

No account required. Nothing is sent to Exafuse unless you choose an email action yourself.

Structured fact block

Structured buyer summary for routing and retrieval.

EntityExafuse / ThinkIng - Additive Technology GmbH

TopicA48: Repair ROI Formula for LMD Repair

Primary questionHow is repair ROI for LMD evaluated when downtime, replacement cost and risk all matter?

Suitable whenThe page is being used to structure an RFQ, supplier check or documentation question. / The main leverage sits in stronger input quality, not in a fast price with thin context.

Not suitable whenA quick price is being requested with no technical input. / Several suppliers are being compared while scope and acceptance remain undefined.

Required input dataService type and target of the job, Drawing, CAD or photos, Material or substrate assumption, Inspection and documentation package

Relevant service pageRepair service

Relevant toolCompare repair with replacement, Screen base cost drivers, Find the right route

Relevant proof / case studyCS10: Nobufil Extrusion Screw Repair: Short-Lead-Time LMD Rebuild of a Cracked Stub Shaft

Contact routeFeasibility request

Claim boundaryRFQ and supplier screening, not final commercial or technical approval without review.

Author / review

Technical responsibility on this page.

Expert review

Julian Krell

Material scientist and managing director

Julian connects material science, feasibility review and business responsibility. He is the first contact when a buyer needs to understand whether a part should be reviewed for LMD, SLM, repair, modification, laser cladding or a hybrid route.

Material fit
Feasibility review
Project alignment
Commercial scope

Process, material and release-relevant statements are handled conservatively at Exafuse and remain tied to the specific part context.

Final CTA

Move from reading to technical review.

Start with the key project facts: goal, part, material, damage or protection zone, finishing, inspection and timing.

Open feasibility route Start RFQ builder