Two Derby rail firms are helping to pioneer the use of 3D printed parts on 海角视频 passenger trains for the first time.
Train leasing firm Angel Trains, which has offices on Pride Park, and engineering consultancy DB ESG, based at the RTC Business Park, in London Road, are part of a consortium that is to trial the first 3D printed parts ever deployed within an in-service passenger train in the 海角视频.
The two firms have joined forces with 3D printing firm Stratasys and train operator Chiltern Railways, to trial 3D printed passenger armrests and grab handles.
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The aim of the trial is to demonstrate how 3D printing can help train operators accelerate the replacement of obsolete parts, helping them to get trains back into service quicker.
Unlike the automotive industry, where vehicles from household brands are mass produced in their millions each year, the number of fleets in the rail industry are comparatively very small and, in some cases, over 30 years old.
This presents a challenge for train operators, especially when it comes to vehicle maintenance and part replacement.
James Brown, data and performance engineer at Angel Trains, said: “In recent times, we’ve seen growing concern among operators that sourcing replacement parts for older train fleets at a reasonable cost and in a short time-frame is proving increasingly difficult.
“The problem is that traditional manufacturing methods only make it cost-effective to produce high volumes of spare parts, even though an operator may only need a few obsolete train parts replaced. In addition, lead times can take months.
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“This is why we have teamed up with DB ESG and Stratasys, showing how operators can overcome these hurdles by using 3D printing to produce the exact amount of parts they need at a fraction of the time and cost of traditional methods.”
Such cost and time efficiencies are exemplified by the armrest feature currently in-service with Chiltern Railways.
According to Mr Brown, the lead time for this part using conventional manufacturing methods would be approximately four months. However, with Stratasys FDM 3D printing, the final armrest can be produced within a week.
Mr Brown said: “This is an exciting time for the 海角视频 rail industry. With this technology, train operators can be much more responsive to replacing passenger-facing parts that get damaged or vandalised.
“A 3D printed replacement part can be produced on-demand and installed immediately. With low-volume production now achievable, we’re also starting to explore how we can leverage 3D printing to customize interiors that are better suited to the passenger commute.
“For example, we’ve tested 3D printing seat back tables with braille informing the passenger that the toilet is 10 rows back from that particular seat.
“This level of customisation is unprecedented and can only be enabled by 3D printing, offering the potential to significantly improve both the servicing of trains and the passenger experience in the future.”
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DB ESG conducted comprehensive testing on a range of industrial-grade 3D printing materials to ensure the parts were industry compliant.
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Martin Stevens, mechanical engineering manager at DB ESG, said: “Achieving certification removes a major barrier that has prevented more widespread implementation of 3D printing across 海角视频 trains.
“Our role in this project has been to investigate the design, production and finishing of the parts, verifying whether they comply with rail standards and checking whether they work in the operating environments.”
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Phil Andrews, interim engineering director at Chiltern Railways, said: “With much of our fleet approaching 30 years old, it’s vital that we can source the parts we need as quickly as possible.
“This trial will play a part in maintaining our industry-leading customer satisfaction scores and ensure our train interiors are maintained to the highest standards.”
With positive responses received from train operators, the consortium is also set to start a trial with Great Western Railway, which plans to integrate 3D printed parts within a selection of trains over the next few months.