Deutsche Bahn – DB is celebrating ten years of 3D printing in rail operations, thereby showcasing with prominence how the technology has indeed moved from being an experimental usage to being the collar pillar when it comes to its maintenance as well as supply chain strategy. Since 2015, the German rail operator has gone ahead and widened its additive manufacturing ecosystem to over 200,000 printed parts, which have been used in over 1,000 applications, thereby making it one of the most advanced rail-related AM programs that exists in the world.
What started with just those simple plastic components, with ten years of 3D printing in rail operations has evolved into quite a broad portfolio of functional tools, electronic test rigs, and interior fittings, as well as heavy-duty metal parts. Early success with basic items like coat hooks went on to encourage DB to go ahead and digitize more of its spare parts library, therefore at the end of the day coming up with the Digital Warehouse, which is a central database that, apparently, now contains more than 1,000 component designs that are ready for on-demand production.
Interestingly, the range of printed parts illustrates how deeply this technology is integrated within DB’s operations. Maintenance teams consistently go ahead and produce custom test fixtures like the printed circuit board testing assembly when it comes to ticket validators, which are created by DB Kommunikationstechnik. They also manufacture handrail signs having braille, hence enabling fast replacement of certain components related to accessibility without waiting for the external suppliers. When it comes to the heavy-duty side, DB has successfully created a 540-kilogram gearbox housing for the shunting locomotives, hence demonstrating that large structural components can also be manufactured additively when the conventional supply chains go on to fall short.
These parts are printed through making use of a variety of processes. Powder bed fusion is used for certain detailed and complex polymer parts having very in-depth geometries, while large metal components are produced by way of a wire or even powder-based processes. Material extrusion also plays quite a major role in creating tools and fixtures, specifically when DB tests alternative materials. There are several depots that happen to be experimenting with recycled filaments, which include the plastic derived from discarded ski boots, so as to further decrease the environmental footprint of production.
One of the major strengths when one talks of DB’s approach is its capacity to produce parts just when they are needed. This eradicates the cost as well as the space needed for stocking slow-moving spares and at the same time also significantly shortens the repair timelines. In cases wherein the manufacturers have discontinued certain older components, 3D printing offers a pathway in order to keep aging trains in service and not retire them prematurely.
DB has also gone ahead and built a countrywide recycling system when it comes to 3D printing waste. Working along with partners, the company goes on to collect failed prototypes, unused prints, as well as other scrap material from sites that are spread across Germany. These are shredded and converted into granules and thereafter extruded back within the new filament on reusable spools. The closed-loop process goes on to keep the materials in circulation and at the same time strengthens sustainability targets of DB.
Notably, additive manufacturing is now taught all throughout the vocational training programs of DB, therefore giving apprentices certain hands-on experience pertaining to design as well as production tools. The company also encourages internal innovation by way of an annual competition, which has gone on to produce creative applications like the camera covers, tanking tools when it comes to ICE trains, and also furniture made out of recycled concrete.
DB, a decade into its additive journey, has shown no signs whatsoever of slowing down. With digital models that are pretty much ready for instant production, recycled materials going forward to enter circulation, and over 1,000 proven use cases, 3D printing can now be termed as a strategic asset for the rail network of Germany. The technology is known to support quicker repairs, decrease manufacturing waste, and also offer a lifeline for parts that no longer exist as far as the traditional supply chains are concerned.
