Unavailable spare parts, long delivery times and high storage costs are among the biggest challenges in day-to-day railway operations. With the 3D printing service from DB Fahrzeuginstandhaltung GmbH – now also available under Railway Services on our website – companies outside the DB group now have access to a tried-and-tested additive manufacturing solution for the first time. Certified. Experienced in the rail sector. Proven in practice.
3D printing, also known as additive manufacturing, is no longer a topic for the future at Deutsche Bahn. For over ten years, 3D-printed components, spare parts and production aids have been successfully used in and around railway operations.
This long-standing experience is now also available via our marketplace, covering everything from component analysis to on-demand production, and ranging from plastic components to safety-critical metal parts. Companies benefit from a fast, flexible alternative to traditional procurement channels – particularly for obsolete, rare or urgently required parts.
Getting started with digital spare parts supply has never been easier. Deutsche Bahn’s 3D printing service combines manufacturing with targeted support throughout the entire supply chain, including:
- Assessment of components’ suitability for 3D printing
- Digitisation and preparation of existing or obsolete parts
- Selection of materials and processes
- Support with testing, certification and approvals
- Demand-driven on-demand production
The cornerstone of the service: both our work processes and our in-house additive manufacturing facility are certified to DIN EN ISO/ASTM 52920 – the comprehensive industry standard for additive manufacturing. The materials used include flame-retardant high-performance plastics and metal alloys that meet the stringent requirements of the rail sector – such as those set out in DIN EN 45545. Even small batch sizes or individual parts can be produced cost-effectively. This allows spare parts to be supplied flexibly, relieves pressure on supply chains and reduces capital tied up.
3D printing in railway operations: Practical examples of its application (excerpt)
Obsolete spare parts – urgently required
Additively manufactured aluminium handrails on seats ensure passengers have a secure grip. If the original spare part is no longer available, 3D printing quickly restores availability, passenger safety and comfort.
Greater safety in the passenger area
3D-printed protective rings, such as those used for emergency call buttons on Berlin’s S-Bahn trains, prevent accidental false alarms. A small component with a big impact: fewer operational disruptions, greater system stability – cost-effectively implemented even for small batch sizes.
Production tools that save time and money
3D-printed assembly, drilling and gluing templates ensure consistent quality and significantly reduce assembly times. Assembly times can thus be cut by up to 75%, and costly rework is avoided.
Digital spare parts instead of full warehouses
Additive manufacturing makes it possible to keep spare parts in digital form and only produce them when needed. This reduces storage costs, increases flexibility and makes companies less reliant on long supply chains – a clear advantage for operators, workshops and maintenance teams.
The future of spare parts supply is digital – and it starts right here, right now.
