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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.

DB Fahrzeuginstandhaltung has been building its expertise in 3D printing since the end of 2015. We cover the entire value chain in cooperation with DB certified partners, identifying which parts are 3D-printable, creating the required CAD data, carrying out the 3D printing and conducting comprehensive quality testing. With over 130 applications and more than 10,000 printed parts made of a wide variety of materials, Deutsche Bahn is the leader in 3D printing in the rail sector.

We are happy to draw on our experiences in order to help others introduce the technology and offer our expertise in arranging concepts, identifying components and implementing solutions in your company in a way that best takes your employees into account.


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
  • Coat hook in passenger carriage
  • Driver terminal housing (locomotive)
  • ICE and switch models for training
  • Large, safety-critical metal parts, e.g. axlebox covers
  • Covers, fan guides, headrests, casings made of flame-retardant plastic or metal

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
  • Partial replacement


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: 900 x 600 x 900 mm
  • Aluminium: 400 x 400 x 400 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