A decision-making framework for field manufacturability of vehicle parts in expeditionary environments

Expeditionary environments (such as remote exploration missions, forward military operations, and disaster response zones) demand adaptive manufacturing solutions to support vehicle sustainment in the absence of traditional supply chains. This work introduces a conceptual mathematical framework for modeling the constraints and trade-offs inherent to expeditionary manufacturing, with a focus on vehicle repair and spare parts fabrication using low-energy and simple automated systems including desktop-scale 3D printers and CNC machines. The model integrates key variables such as energy availability, material transport cost, fabrication time, and environmental limitations to support rapid decision-making on part manufacturability and in-field feasibility. A case study involving the on-demand production of some common wear and failure parts on a vehicle, including suspension components and the water pump, is used to demonstrate how this framework can guide the selection of suitable manufacturing technologies, part redesign or repair for field printing. This modeling approach highlights how predictive modeling can optimize both component geometry and process parameters to meet requirements while minimizing energy expenditure and logistics overhead. This work informs future efforts in resilient vehicle system design by embedding manufacturability considerations into the early stages of development, particularly for platforms intended for deployment in expeditionary environments. It offers practical guidance to designers, logisticians, and mission planners seeking to integrate field-capable manufacturing into vehicle lifecycle support.