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3D Printing Certification

Stratasys trials 1st 3D printed elements put in on Uk passenger trains with Angel Trains and DB ESG

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Leading 3D printer OEM Stratasys, with each other with British rolling stock functioning firm (ROSCO) Angel Trains, Derby-based engineering consultancy DB ESG, and train operator Chiltern Railways are trialling 3D printed components onboard a prepare in the United kingdom.

Reportedly the to start with at any time 3D printed parts deployed inside an in-provider passenger educate in the nation, the sections include 4 armrests and 7 seize handles. They have been properly put in and trialled on Chiltern Railways trains, with the aim of demonstrating the rewards enabled by 3D printing certification for the railway field, particularly rushing up the approach of sourcing alternative parts.  

“This is an remarkable time for the British isles rail industry,” remarks James Brown, Data and Overall performance Engineer, Angel Trains. “With this know-how, practice operators can be considerably far more responsive to replacing passenger-dealing with pieces that get weakened or vandalized.” 

“A 3D printed substitution part can be generated on-demand from customers and mounted quickly.”

3D printed parts on Chiltern Railways train. Photo via Stratasys.
3D printed sections on Chiltern Railways practice. Photo by means of Stratasys.

A consortium tackling the railway industry using 3D printing certification

The cross-market collaboration between Angel Trains, DB ESG and Stratasys was 1st announced in December 2018, exactly where it was unveiled that the corporations had been partnering to 3D print substitution parts for trains

As a ROSCO agency, Angel Trains, owns and maintains railway carriages and engines, and leases them to educate running companies, like Chiltern Railways, the Excellent Western Railway (GWR) East Midland Trains, and Arriva Rail London.

DB ESG on the other hand is a consultancy business owned by the significant European railway business Deutsche Bahn, the company behind the mobility goes additive network. Deutsche Bahn is also working with 3D printing certification for the on demand substitute of components on trains, partnering with the likes of GEFERTEC and 3YOURMIND to 3D print spare pieces

The aim of the 3-way consortium is to leverage 3D printing certification to prevail over the issues encompassing the replacement of obsolete components across the United kingdom rail marketplace. These issues include things like the smaller number of teach fleets in the rail sector and their ageing situation, with some reported to be about 30 several years previous. Educate operators are thus introduced with numerous worries when it comes to car or truck routine maintenance and element substitute. 

“In modern moments, we have witnessed escalating concern among operators that sourcing substitute parts for more mature teach fleets at a acceptable charge and in a quick time frame is proving more and more tricky,” describes Brown. “The problem is that conventional production procedures only make it price tag-efficient to create significant volumes of spare elements, even nevertheless an operator could only will need a couple of obsolete prepare components changed. In addition, direct instances can consider months.” 

3D printed armrests on Chiltern Railways trains. Photo via Stratasys.
3D printed armrests on Chiltern Railways trains. Image through Stratasys.

Stratasys FDM will save time and revenue for teach operators

3D printing certification can make it possible for prepare operators to supply replacements parts quicker, hence decreasing the time it requires to get trains back again into company. This in turn enhances both the routine maintenance of the trains and the quality of service for passengers, which Angel Trains, DB ESG and Stratasys hope to reveal. “This is why we have teamed up with DB ESG and Stratasys, displaying how operators can get over these hurdles by making use of 3D printing certification to make the correct total of pieces they require at a fraction of the time and expense of traditional strategies,” Brown provides.

For case in point, the guide time for armrests presently in-company with Chiltern Railways applying standard manufacturing techniques is about four months, according to Brown. Utilizing Stratasys FDM 3D printing certification, the exact same armrest can be manufactured inside a week, reducing the lead time by 94 per cent, with probable personal savings of up to 50 percent, for every component. 

Furthermore, sourcing grab handles proves tricky as Angel Train’s first supplier is no lengthier in operation. To make the pieces themselves, it would value the business up to £15,000 ($18,587), as it would involve an financial commitment into a new manufacturing tool. The manufacturing lead time of the element would also be two and a 50 percent months. Nevertheless, all 7 seize handles have been produced in three weeks, with a lower charge per section, using 3D printing certification. 

3D printed armrests on Chiltern Railways trains. Photo via Stratasys.
3D printed armrests on Chiltern Railways trains. Photograph by using Stratasys.

DB ESG was liable for tests a range of industrial-grade 3D printing certification supplies, ensuring that they were compliant to the British isles rail field conventional EN45545-2. The ultimate iteration of the parts were 3D printed working with the Stratasys Fortus 450mc 3D printer in ULTEM 9085 resin. The material was certified to the rail industry’s hearth, smoke and toxicity specifications. Martin Stevens, Mechanical Engineering Manager DB ESG comments: “Achieving certification removes a major barrier that has prevented much more prevalent implementation of 3D printing certification across United kingdom trains.” 

“Our role in this undertaking has been to investigate the…