Applications of 3D printing in the railway industry

August 2, 2024
3D printing, additive manufacturing, Italy, just in time, mobility, on demand, Puglia, railway industry, Renfe, Roboze, SNCF, spare parts, sustainability, Train

3D PRINTING FOR SPARE PARTS IN THE RAILWAY INDUSTRY

The production of spare parts for the railway industry is faster and quicker with 3D printing by Roboze, a leading Apulian company in the sector

Present in many industrial sectors, 3D printing – or, more correctly, additive manufacturing – is also gaining ground in the railway industry. The technology offers many advantages to operators in the sector, especially in terms of speed and production costs. Whether designing armrests, seats, or other components for trains, additive manufacturing has proven to be a more than valid alternative on many occasions.

The railway industry faces the constant challenge of availability and costs associated with the production of spare parts. To address these challenges, the sector is looking with increasing interest at innovative solutions, such as additive manufacturing. This technology not only improves production efficiency but also represents a significant step forward towards greater sustainability and innovation in the transportation industry.

The importance of on-demand production of spare parts in the railway sector

The railway sector is increasingly seeking new on-demand production methods for manufacturing spare parts.

Handles, hinges, support surfaces such as tables and seats require frequent maintenance. Parts often become obsolete after several years, and it becomes increasingly complex to source them because they may not be available, and their production in limited quantities would not justify costly investments.

Train armrests, for example, have a complex design, and there are numerous varieties of models available depending on the type of train and the railway company considered. Given their function, the supply of this component is necessary to ensure comfort but at the same time maximum safety for passengers. When armrests on trains are damaged, it can be difficult to find replacements, and new or spare parts are not always immediately available. If the railway company does not have stocks in the warehouse, which involve a logistical cost, it is necessary to order parts with long waiting times.

The repair of the part, therefore, is subject to the timelines of external suppliers, which can slow down the entire process. If it is not possible to repair the damaged part, it may be necessary to replace the entire armrest, generating considerable waste of still intact material.

Advantages and benefits of additive manufacturing, the case of Germany

In countries like Germany, many railway companies are investing to increase their 3D production capacity, aware of the advantages and benefits obtained with additive manufacturing techniques. The possibility of producing out-of-production spare parts on demand allows companies to bypass the expense associated with a new production run of the needed component, significantly reducing costs and time associated with maintenance and downtime.

Additive manufacturing for train maintenance in France

SNCF, one of the main players in the French railway industry, has integrated additive manufacturing into its activities to design spare parts more quickly and thus avoid long downtimes. In 2021, SNCF, the managing body of French Railways, had announced the integration of specific software to identify and qualify spare parts that could be 3D printed. At the time, the solution had estimated that parts 3D printed with additive manufacturing had reduced delivery times by 85%, statistics that have certainly increased since then.

The Spanish company Renfe 3D prints spare parts

Renfe is the main railway transport company in Spain and has a production and maintenance division that integrates a series of 3D technologies for the development of spare parts. The company’s pilot center integrates an area with equipment for 3D printing of polymers, as well as a section dedicated to post-processing and another with 3D scanning and reverse engineering solutions. The integration of these new technologies allows Renfe to create spare parts, with significant cost and time savings in parts production compared to other traditional methods.

With the implementation of additive manufacturing solutions, railway companies can now replace metal parts traditionally machined by chip removal, significantly reducing costs and delivery times.

This is exactly what Roboze – a company born and grown in Bari but now global, with offices in Milan and Houston, USA, and which is becoming an international reference for additive manufacturing applied to the railway sector – does. Roboze is the specialist in additive manufacturing for high-performance materials. Its solutions have in fact been chosen also by Hitachi Rail, a major player in the railway sector.

Roboze 3D printing: advantages for the railway sector

Roboze has developed a technological ecosystem to help traditional manufacturing produce differently and more intelligently and scalably, with less waste and fewer emissions, to give companies the ability to build small series or unique products in-house.

Roboze sells printers but also materials, know-how, and technological infrastructure, so as to make companies independent in production. Roboze 3D printing solutions allow companies to digitize their warehouse, producing parts on demand and just in time. It is possible, in fact, to produce components even of small dimensions, with complex geometries having maximum design freedom, thus internalizing the entire process and avoiding having to outsource supplies. In this way, it is possible to obtain a significant reduction in warehouse costs, supply times, and waste.

Roboze’s “on-demand” printing is also innovative in its model: Roboze has created a cloud network with all Roboze 3D printers present in the world, thus giving anyone the possibility to exploit the network, creating the piece they need when and where they need it, reducing transport costs and CO2 emissions. You prepare the file, insert it into the system, Roboze technicians study the feasibility, and after approval, they send the piece to print at the location chosen by the customer, at the moment when the printer is not being used.

A concrete example of the advantages of its innovative technology for the rail sector is the collaboration between Roboze and Hitachi Rail.

Roboze for Hitachi Rail

Hitachi Rail has also chosen a ROBOZE solution, the ARGO 500, to operate in the high-tech plant in Naples and implement an industrial 3D printing technology using materials such as ULTEM 9085 and Carbon PEEK for the production of spare parts for its trains.

The advantages of additive manufacturing for Hitachi Rail

Thanks to the collaboration with Roboze, Hitachi Rail will be able to exploit its advanced 3D printing solution to produce prototypes and spare parts for its trains. With the implementation of this solution, Hitachi Rail can now replace metal parts traditionally machined by chip removal, significantly reducing costs and delivery times.

This partnership allows for the use of 3D printing to improve operational efficiency and reduce production costs of railway prototypes and spare parts.

From Italy to the USA

Hitachi Rail will soon open a state-of-the-art train factory in Washington County, Maryland. The factory, destined to deliver the new fleet of 8000 series railcars for the Washington Metropolitan Area Transit Authority as its first order, will leverage the technological expertise of the entire Hitachi Group to be its most advanced digital site. Thanks to the collaboration with ROBOZE, Hitachi Rail will be able to exploit its advanced 3D printing solution to produce prototypes and spare parts for the railway sector.

The collaboration between Hitachi Rail and Roboze extends beyond the simple supply of machines. Hitachi Rail will also benefit from engineering services and consulting from Roboze expert teams both in the United States and in Italy, ensuring continuous and highly specialized support.