Company’s Rail Industry Solution Designed to
Meet Requirements for Passenger Trains and Light Rail, With
Materials Passing European Standard EN45545-2
At a press conference at the Formnext 2019 trade fair, Stratasys
(NASDAQ: SSYS) announced its Rail Industry Solution to help
passenger trains – from long-haul to urban metros – run on time
more frequently and potentially save thousands of euros a day. By
using its ULTEM™ 9085 resin and Antero 800NA material with
Stratasys Fortus 3D printers for production, rail operators will be
best positioned to leverage additive manufacturing for the
production of spare parts on demand that meet strict government
certification requirements for smoke, fire, and toxicity. Both
materials have passed the European Union’s Rail Standard,
EN45545-2.
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Customized 3D printed air vent system
produced by Bombardier Transportation on Stratasys' large-scale
F900 3D Printer (Photo: Business Wire).
The Stratasys ecosystem of customers and partners benefiting
from the Rail Industry Solution currently includes Angel Trains,
Bombardier Transportation, Chiltern Railways, DB ESG, and Siemens
Mobility.
Stratasys’ additive manufacturing consultancy, Blueprint, has
estimated that for one major U.S. commuter rail service, every day
a train set is out of service costs €18,000, and often a single
part that would ordinarily cost less than €100 is all that keeps
the train from running. Compounding the challenge, the service life
of trains is typically 35-45 years making sourcing spare parts a
challenge. By turning to additive manufacturing, train operators
can get the parts they need within a day or two regardless of the
uniqueness of the part or the age of the train car, minimizing time
spent in a maintenance yard and dramatically reducing costs.
“In industry after industry, we continue to see organizations
discover how additive manufacturing improves customer service,
streamlines maintenance and operating costs, and helps engineer
lighter, durable products,” Stratasys EMEA President Andreas
Langfeld said. “Rail is no exception. The old model of keeping
trains running through expensive physical inventory or slow and
costly traditional manufacturing is being replaced by digital
inventory and on-demand 3D printing. Indeed, this is exemplified by
some of the biggest names in European passenger rail.”
Part of Deutsche Bahn, DB ESG, based in Derby, U.K., helps train
operators and rolling stock owners keep trains in service by
reverse engineering obsolete components. “Additive manufacturing
allows us to efficiently produce parts for the passenger
environment that are indistinguishable from the existing parts,”
said Martin Stevens, Mechanical Engineering Manager at DB ESG. “The
Stratasys range of EN45545-2-compliant materials enable us to
reverse-engineer parts, such as interior grab handles, with
freeform curves that traditionally could only be made with casting
or injection molding, without the need for expensive tooling, and
with a corresponding reduction in delivery times. Stratasys’
GrabCAD Print software allows us to precisely define the printing
parameters, then lock down the print file to ensure consistent
parts production across multiple printing bureaus.”
Stratasys rail-qualified materials include ULTEM 9085 resin, a
flame-retardant, high-performance thermoplastic that has passed
European standard EN45545-2 for all three Hazard Levels – HL1, HL2
and HL3. It features a high strength-to-weight ratio, excellent
heat resistance, and high-impact strength. Also included is Antero
800NA, a PEKK-based thermoplastic possessing mechanical properties
such as high strength, high heat resistance, toughness and wear
resistance. The material is compliant with EN45545-2, permitting it
to be used to produce a wide range of components. Both work with
Stratasys Fortus 3D printers built specifically for manufacturing
and heavy industries, with large build sizes, high part accuracy
and repeatability, and compatible with the new GrabCAD Shop
software, which streamlines work order management for centralized
3D printing shops.
German manufacturer Bombardier Transportation is using the
Stratasys Rail Industry Solution to accelerate the development
process of new trains, including 3D printing interior and exterior
train parts, such as air ducts, housings and cable holders. “Our
goal during the development process for new trains is to speed up
the production of project-specific parts that take a while to
design,” said André Bialoscek, Head of Vehicle Physical Integration
for Bombardier in Henningsdorf, Germany. “While accelerating
production, we still need to ensure that total functionality,
safety, and repeatability are upheld. With Stratasys’ Rail
Solution, we are able to do all those things – it has been a
game-changer for our department.”
Angel Trains, one of the U.K.’s leading train leasing companies,
is using the Stratasys Rail Industry Solution to manufacture a
range of direct replacement parts including passenger arm rests,
grab handles and equipment covers. “Sourcing obsolete replacement
parts for older train fleets within short timeframes and at
reasonable costs is becoming increasingly difficult and presents
several challenges for train operators,” said James Brown, Data and
Performance Engineer, Angel Trains. “Stratasys Rail Qualified
Materials and production-grade Fortus machines enable us to design
and manufacture replacement parts quickly and reliably that meet
all required railway standards. As such, we’re able to lower costs
and lead times while reducing engineering time spent on managing
obsolescence issues. This exciting technology gives rail operators
peace of mind over their supply chain for older fleets and will
ensure improvement to passenger experience in the future.”
Learn more about Stratasys rail solutions and then explore
Blueprint’s analysis of the business drivers of 3D printing in
light rail applications.
Stratasys is a global leader in additive manufacturing or
3D printing technology and is the manufacturer of FDM® and PolyJet™
3D printers. The company’s technologies are used to create
prototypes, manufacturing tools, and production parts for
industries, including aerospace, automotive, healthcare, consumer
products and education. For 30 years, Stratasys products have
helped manufacturers reduce product-development time, cost, and
time-to-market, as well as reduce or eliminate tooling costs and
improve product quality. The Stratasys 3D printing ecosystem of
solutions and expertise includes: 3D printers, materials, software,
expert services, and on-demand parts production. Online at:
www.stratasys.com, http://blog.stratasys.com and LinkedIn.
Stratasys and FDM are trademarks or registered trademarks of
Stratasys Ltd. and/or its affiliates. ULTEM™ is a registered
trademark of SABIC or its affiliates. All other trademarks are the
property of their respective owners, and Stratasys assumes no
responsibility with regard to the selection, performance, or use of
these non-Stratasys products.
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Media Contacts Stratasys Corporate & North
America Craig.Librett@Stratasys.com +1 612-364-3208
Europe, Middle East, and Africa Jonathan Wake / Miguel
Afonso, Incus Media stratasys@incus-media.com +44 1737 215200
Asia Pacific and Japan Alice Chiu
alice.chiu@stratasys.com
Mexico, Caribe Carlos.ramirez@stratasys.com 00+52 (55)
15349791
Brazil, Central America and South America
Erica.massini@stratasys.com +55 (11) 2626-9229
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