Replique and Alstom expand global 3D-printing supply chain for rail spare parts

Replique is expanding its collaboration with rolling-stock manufacturer Alstom worldwide. What began as individual manufacturing orders for comparatively simple components such as door stops or tank caps has, according to the companies, developed into a long-term partnership. Replique acts as a central supplier for several Alstom country organizations, including in Singapore, Brazil, Australia, and across multiple European markets.

From a technical perspective, the model aims at a standardized, cross-site supply of parts in which 3D printing is combined with conventional processes depending on component requirements. For each part, Replique assesses whether additive manufacturing, CNC machining, casting, or forging makes economic and technical sense, and—where required—handles the entire process from design and qualification through post-processing, quality assurance, and delivery. For Alstom, the audit approach is particularly relevant: a single audit is intended to be sufficient to access a partner network of more than 350 suppliers; for safety- or function-critical components, additional on-site qualifications are предусмотрed.

According to Replique, production volumes in the low five-digit range have already been manufactured for Alstom, including parts made from stainless steel as well as flame-retardant plastics.

“We are proud to deliver solutions to Alstom worldwide that make their parts supply more efficient and flexible. Our components are used in series operation. Each project shows us how diverse the challenges in parts procurement are and motivates us in our vision of a globally networked, sustainable, and efficient supply chain,” says Dr. Max Siebert, CEO and Co-Founder of Replique.

Concrete examples illustrate the role of 3D printing in maintenance and obsolescence management. In Asia, a single impeller of a cooling system was manufactured using metal 3D printing and then balanced, milled, and corrosion-protected by coating, instead of replacing an entire unit. In Italy, Replique secured the production of cast charge-air coolers for a train from the 1960s using 3D-printed casting molds. For new train series, logo plates are also produced worldwide.

“Replique doesn’t just supply us with the parts; it guarantees consistently high quality worldwide. This is particularly crucial for series parts,” explains Lorenzo Gasparoni, Alstom 3D Printing Program Manager. “Replique has completed the entire series approval process, including first article inspection and initial assembly—with excellent results.”

This positions 3D printing primarily as a building block of a qualified, globally scalable supply chain designed to make spare parts available faster and keep variants manageable.