Rolling stock consultancy DB ESG, which provides rolling stock engineering solutions, has expanded its innovative work in 3D printing to offer Digital Manufacturing (DM) services to the UK rail industry.

The expansion has been driven by significant growth and development in this business area.

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Since 2018, DB ESG has been using the technology to address component supply issues and solve engineering problems on over 93 individual projects for 20 different customers.

The company’s approach has solved engineering and operational problems that have enabled vehicles to remain operational and improved the overall efficiency of the UK’s rail industry.

An extensive range of materials are suitable for 3D printing, including carbon-reinforced materials, flexible polymers, and various metals.

Using 3D printing allows single units to be supplied, avoiding the need to order large minimum quantities, removing the need for storage, and keeping costs low. Delivery times can also be within days instead of typically months for traditional manufacturing.

Digital Manufacturing encompasses the design, development, and production of physical parts by using computer-aided processes such as Additive Manufacturing (also known as 3D printing) and programmable CNC machines.

The process not only combats obsolescence, but can also be used to address component failures. It also allows design changes to be made to improve the reliability and quality of parts, and allows newer materials and technologies to be incorporated.

Digital manufacturing also enables bespoke components to be created from scratch, jigs and tooling for depots, and rapid prototypes for larger integration projects.

DB ESG was established in 1995. It is part of DB Systemtechnik, one of Europe’s largest rolling stock consultancies in Europe, and its world-class experts and solutions add value to both its customers and the UK rail sector.

The company has also developed an online Digital Manufacturing Hub with a catalogue of parts that is both an educational and procurement tool where parts can be ordered online.

Further information about digital manufacturing can be found online at www.3dbesg.co.uk

HS2 is already using 3D printing to produce reinforced concrete on-site which cuts the amount of concrete, reduces carbon emission by up to 50%, and in Germany, Siemens is incorporating a 3D printing facility at a new depot under construction in Dortmund,

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.

Daniel Hartley, DB ESG Digital Manufacturing Business Lead

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.

Nick Goodhand, DB ESG Managing Director