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3D printing expertise for your business

To develop new solutions, Deutsche Bahn AG has joined the cross-industry "Mobility goes Additive" network.

In the area of 3D printing we are focusing on rapid spare parts availability in order to reduce system downtimes and safeguard the future viability of our company.

Over 1,000 parts were printed within the first year. More than half of the 3D-printed parts are being tested during operation.

We are happy to share our experience with the introduction of the technology in our own company and offer you our expertise, from conceptual design through component identification to implementation in your company.


3D printing application examples

  • Terminal box for ICE 1/2 traction motor
  • Sand mould for box lever for load brake machine
  • Dust cover for brake system
  • Air grille for locomotive air conditioning system
  • Clamping block for sunblind
  • Coat hook in passenger carriage
  • Driver terminal housing (locomotive)

Improving spare parts availability

  • Replacement for obsolete or hard-to-come-by spare parts
  • Establishment of second sourcing

 

Reducing downtimes

  • Reducing system and vehicle downtimes
  • Shortening delivery and order times

 

Reducing costs

  • Reducing non-recurring costs (tool-free manufacturing)
  • Reducing storage costs (production on demand)
  • Avoiding minimum order quantities

 

Speeding up decision-making processes

  • Visualisation of new developments, design and model enhancements (rapid prototyping)
  • Better communication
  • Tangible models
  • Longer service life thanks to optimised, improved components
  • Requirements-based rather than production-based designs
  • More efficient use of resources
  • Sustainability

Possible applications

  • Obsolete components
  • Small volumes with high costs
  • Accident repair work
  • Tools
  • Prototype construction


Component requirements

  • Independent of safety aspect
  • Simple or complex geometry
  • Costly conventional
  • production


Availability

  • Risk of system failure (train, locomotive, etc.)
  • Components with long delivery times

 

Specification for manufacturing

  • In accordance with manufacturer specification
  • With reverse engineering
  • In accordance with specification
  • Optimised component (better part)

 

Materials

  • Tool and stainless steels
  • Aluminium (titanium, Inconel, CoCr)
  • Polyamide 12, ABS, PEEK
  • Ultem (flame retardant)

 

Maximum component size

  • Plastics: 914 x 610 x 914 mm
  • Aluminium: 630 x 400 x 500 mm
  • Steel: 250 x 250 x 300 mm
  • Analysis of potential specifically for your company
  • Identification of suitable parts
  • Joint testing of technology
  • Preparation of a business case
  • Especially in the case of obsolete parts, 3D printing offers the advantage of being able to produce small quantities without one-off costs or minimum order quantities
  • Reverse engineering for your problematic parts in accordance with
    • the manufacturer's specifications
    • Specimen (e.g. by means of 3D scan)
  • Optimisation/enhancement of components