A collaborative project between the National Manufacturing Institute Scotland (NMIS) and the Harris Tweed Loom Spares Co. demonstrates how additive manufacturing can support traditional craft processes. The focus is on the maintenance and servicing of the complex looms required for the production of the legally protected Harris Tweed. As these looms can only be operated in the homes of weavers in the Outer Hebrides, their operability is central to the economic stability of the region.
The challenge lies in the limited availability of spare parts. Many components are no longer commercially available and have to be reproduced at great expense. In some cases, procurement can take up to six months. To address this problem, a new assembly design was developed as part of the collaboration that uses 3D-printed spare parts. Engineering teams at NMIS tested different material combinations and developed a solution in which a component previously consisting of seven individual parts was reduced to three components that can be additively manufactured from a high-performance composite material.
The new design makes it possible to produce spare parts on site on low-cost desktop 3D printers within two hours. This not only significantly reduces production costs, but also shortens downtimes. Weavers like John Bennie, who previously had to make do with improvised solutions – such as rebuilding a Ford Ka flywheel – report significantly improved workflow.
John said: “When a vital part of the loom breaks, it can halt production for weeks, which is incredibly frustrating. Finding a way to keep the loom running smoothly is essential, and it’s been great to be one of the first to try out the new 3D-printed assembly. The ability to get what we need, when we need it, will make a huge difference, as it means we can minimise downtime and focus on our work without unnecessary interruptions.”
Kelly MacDonald, operations manager at The Harris Tweed Authority, said: “We take pride in our craftsmanship and tradition, but we also know that innovation is vital for keeping our industry strong for the generations to come. Working with NMIS is a significant step forward in future-proofing the looms critical to the production of Harris Tweed. With the ability to replace parts quickly, easily, and affordably, our weavers can focus on what they do best without worrying about delays. This not only safeguards the future of our fabric but also supports the livelihoods of the island community who dedicate their skills to preserving the craft.”
In the long term, the aim is to develop modular components that can be flexibly adapted to individual looms. The aim is to maintain a balance between technical modernization and the preservation of traditional manufacturing processes.
Andrew Bjonnes, research & development engineer at the NMIS Digital Factory, added: “This project really showcases how modern manufacturing can boost traditional industries and help preserve valuable heritage skills. With additive manufacturing, we’re promoting self-sufficiency and giving weavers a smart, cost-effective, and user-friendly way to keep their looms up and running. It has been an incredibly rewarding project, making a tangible difference and allowing weavers to concentrate on their craft instead of worrying about equipment failures.”
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