FEATURE PHOTO: ISTOCKPHOTO.COM
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Bringing 3D printing
to the UK rail industry
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D printing is an almost magical process, yet, in a way, it is also so simple. A normal ink-jet computer printer lays down a film of ink onto a sheet of paper to produce letters, words or an image. Now use thicker ink, and go over the image several times, and a three-dimensional shape starts to form.
Replace the ink with plastic or metal powder, and the paper with a sheet that can be peeled off once the printing is finished, and that’s the essence of 3D printing. The size of the object is only limited by the size of the printer, and the thickness depends on how may layers are put down - how many times the print head goes over the same area.
Rail Engineer first became aware of the process in 2013, when Hobs 3D created a model of the upgraded King’s Cross station from the original computer-aided design (CAD) files, making the model extremely accurate. Since then, 3D printing, now also called Additive Manufacturing (AM) as material is added through the process,
has become a bona-fide manufacturing technique, used to make components for all types of equipment, including railway trains. Derby-based DB ESG is part of a cross-industry partnership that is leading the way by being the first to apply 3D printing to the UK rail industry, providing engineering design, assessment and approvals for the introduction of 3D printed components on UK train fleets. Working together, Angel Trains, Stratasys and DB ESG have, to date, produced eight fully approved components using AM. Some of these parts are currently being trialled on in-service passenger trains by Chiltern Railways. This is the first time production-ready 3D printed parts have been fitted on passenger trains within the UK.
Unique manufacturing challenge Manufacturing for rolling stock is expensive, with train fleet production runs being of low volume compared to other manufacturing industries. This low volume drives up the manufacturing cost, removes the incentive to invest in research and development, and reduces the number of suppliers able to compete.
Model of King’s Cross station produced by Hobs 3D in 2013. Rail Engineer | Issue 181 | Jan/Feb 2020
