DB ESG expands 3D printing services for more efficient rail components

DB ESG, a leading provider of engineering solutions for rail vehicles, has successfully expanded its Digital Manufacturing (DM) services. Since 2018, the company has been using 3D printing technologies to solve component supply issues and overcome engineering problems in over 93 projects for 20 different clients. This innovative approach has helped to keep vehicles in service and increase the efficiency of the UK rail sector.

DB ESG now offers an extensive range of 3D printed materials, from carbon-reinforced or flexible polymers to various metals. The manufacturing processes, particularly 3D printing, enable single unit delivery, avoid high minimum order quantities, eliminate stock holding requirements and keep costs down. Components can be delivered within days rather than months, as is the case with conventional manufacturing processes.

Daniel Hartley, Digital Manufacturing Business Lead for DB ESG said: A clear commercial strategy was set up for DM, including 3 clear business streams: obsolescence, bespoke components, and 3D scanning. Alongside the commercial strategy, a technical strategy has been established focused on research and development into different materials, new technologies, and innovative processes. This has provided us with endless use cases and established our position as the market leader for Rolling Stock Digital Manufacturing.”

Nick Goodhand, Managing Director, DB ESG added: “We were the first in the UK to place 3D printed parts into commercial service on a passenger train in 2019. Since then, we have rapidly expanded our offering and have provided Digitally Manufactured components and services to major OEMs, TOCs and ROSCOs. From individual parts to entire fleet fitments.”

DM involves the design, development and production of physical parts using computer-aided processes such as additive manufacturing (3D printing) and programmable CNC machines. DM is not only used to combat obsolescence, but also to improve components, including the use of newer materials and technologies. DB ESG has also developed a Digital Manufacturing Hub with a parts catalog that serves as both an educational and procurement tool through which parts can be ordered online.