Deutsche Bahn has produced 200,000 parts using 3D printing in 10 years

At Deutsche Bahn, 3D printing has now become part of the standard toolbox for maintenance. Additively manufactured components are produced at several facilities, including headrests for IC seats, fan wheels, lamp holders, or protective housings in signal boxes. Since 2015, more than 200,000 spare and series parts have been produced for over 700 different applications. Many of these components would, using conventional methods, only be available with long lead times or no longer be available at all because original tools and supply chains no longer exist.

Various additive manufacturing processes for plastics and metals are used. While the first applications were predominantly produced with polymer-based processes, the railway now also uses metal processes for highly stressed components. Before approval, all parts undergo standardized test programs, including fatigue tests and function-specific tests in regular operation. The goal is to integrate components with known mechanical properties into the existing maintenance and approval process and thus safeguard the operability of the fleet.

A central role is played by the complete digitization of geometries. Defective or no longer available components are captured via 3D scanning and then reconstructed as CAD models. These datasets are used to create either direct print data or negative molds that can be reused in casting. The models flow into a digital spare parts warehouse from which demand can be triggered at short notice without having to maintain physical stock for rarely needed parts.

Manufacturing takes place both in the company’s own maintenance facilities, such as in Nuremberg and Neumünster, and at external service providers. Through the “Mobility goes Additive” network initiated by Deutsche Bahn, numerous manufacturers and suppliers are also involved. For the rail industry, this creates an ecosystem in which additive manufacturing not only covers individual prototypes, but is increasingly becoming a structural component of the spare parts strategy.