MATERIALS Numerous 3D printing materials
have been developed in recent years to comply with the standard. These include high-performance polymers, such as PEKK and PEKK-A by 3D printing filament manufacturer Kimya, and ULTEM 9085 by chemical manufacturer Sabic. Such ‘open market’ materials have already been widely used across the rail sector to deliver safe products while minimising production and compliance costs. ULTEM 9085 is widely used in
the rail, aerospace, and automotive industries, as its properties meet the requirements of the most demanding industrial applications. The combination of high chemical and temperature resistance, and flexural and tensile strength makes the material an attractive option for the rail industry. Moreover, it’s easy to machine and offers low flammability and toxicity. Fused Filament Fabrication (FFF),
as well as Selective Laser Sintering (SLS), are 3D printing techniques often used in the industry due to their ability to produce parts with high- performing thermoplastic qualities. SLS is a powder-based 3D printing technology that fuses material layers into a final part using lasers, while FFF is a material extrusion process, building an object by depositing melted material layer by layer.
SPARE PARTS ON TRACK 3D printing company Roboze delivers on-demand, just-in-time manufacturing of spare parts to the rail sector, reducing costs associated with storage and pre-ordering for operators. 3D printing allows several components to be integrated together, enhancing the original design of a component rather than merely replacing it. In suitable applications, Roboze can
replace metal with high-performance plastics, reducing weight by 50% which leads to lower energy and fuel consumption. The environmental impact of the overall rail vehicle is also decreased, as more lightweight components require less material during production. Roboze’s ‘digital warehouse’ contains digital blueprints of spare parts. So, only when a part is required is the blueprint sent for printing and the part produced. This process cuts cost and manufacturing times, while reducing the spare part inventory requirements for rail operators. In terms of 3D printed materials,
Roboze uses polypropylene for flapper replacements on train toilets due to its wide chemical compatibility, low weight, and impact resistance. The company replaces toilet drain pumps using Carbon PA because of its strong mechanical properties compared to
Designing and optimising rail spare parts in Siemens Mobility’s CAD programme
aluminium AA1050A. Meanwhile, low FST evolution, UL94-Vo at 1.5mm and 3mm or 0.059in and 0.118in makes ULTEM 9085 a suitable material for 3D printed armrest replacements.
ARMED WITH AM Kimya – the additive manufacturing (AM) division of technology company Armor – provides 3D printing materials and services for the rail industry. Kimya entered the railway parts arena in 1982 when a supplier ordered a small batch of polymer parts through its manufacturing service. The original mould no longer existed, so the parts had to be redesigned from scratch using a PEKK filament developed in-house at the research and development centre. 3D printing the protective covers using PEKK led to cost savings and reduced lead times. No digital twin or mould was
available for reference, so a single paper plan was used by engineers and an original part was made using PVC as a prototype. A PEKK SC version was able to be printed using the PVC plan and could be applied to end-use. The custom PEKK SC filament was used due to its ability to resist high temperatures, up to 260°C, as well as flame retardant capabilities, abrasion resistance, and chemical resistance.
ON THE RAILS Many rail companies have turned to 3D printing in one form or another in recent years to fulfil their spare parts supply, enhance component design or improve the environmental footprint of their rail vehicles. German railway company Deutsche
Bahn, for instance, has taken advantage of 3D printing using Gefertec’s 3DMP technology. The process creates near-net-shaped metal blanks using wire as a raw material at fast speeds and has a build-up rate of 600cm3
per hour, making it
suitable for steel, nickel-base, titanium, or aluminium. Gefertec’s technology boasts cost savings of up to 60% with nearly 100% material utilisation, borderline eradicating waste. The company uses 3yourmind software to enable digitising logistics. Additionally, Gefertec’s technology
has been deployed for the production of wheelset bearing covers for class
14
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