Deutsche Bahn saves millions with 3D-printed spare parts
Deutsche Bahn has been relying on 3D printing for ten years and already has over 200,000 components in use. This saves millions of euros.
A template from the 3D printer used at Deutsche Bahn.
(Image: DB AG / Max Zimmermann)
What do a fan wheel for overhead line revision railcars, a bracket for a 1st class train reading lamp, and a diffusion grille for a reading lamp have in common? They all come from the 3D printer at Deutsche Bahn as spare parts. DB has been relying on 3D printing for ten years now. For its anniversary, the state-owned company drew a balance sheet.
Over 200,000 components from the 3D printer are already in use. The fast and efficient availability of spare parts has saved over 20 million euros. In many cases, the 3D printers helped the railway to obtain spare parts at all, for example for components in the ICE 1 that are no longer manufactured. Or, for example, templates and covers were created that helped to install new luggage racks without accidentally scratching other parts – in a fraction of the usual time.
Twelve different printing processes
3D printing has long since left the experimental stage. According to its statements, DB uses twelve different printing processes, including with metal, plastic, and sand. The printed parts range from the 540-kilogram gearbox housing to handrail signs with Braille, tablet holders, and drilling templates to coat hooks.
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By 2030, the railway aims to digitize ten percent of all spare parts in vehicle maintenance, DB explained in an interview on the website of the 3D printer manufacturer Formlabs. One challenge is to meet the strict safety requirements that apply in rail transport.
Also in use for the ICE L
The railway therefore also uses 3D printing for work on new vehicles: For the ICE L, a 3D-printed, yellow template is used to help accurately apply pictograms that passengers can use to orient themselves in the train – for example, the labeling of BahnBonus areas or the QR codes for customer feedback.
For the production of components, DB relies on its printers and its partner network. In the "Mobility goes Additive" network, established in 2016, the railway collaborates with 140 companies from industry and research to jointly drive innovation.
Templates for 3D printing are stored in a central database, the Digital Warehouse. According to the railway, there are currently over 1000 virtual models there. This corresponds approximately to the status that was also reported two years ago.
(mki)
