HVE's Tool-Free 3D Printing for Rail Components: A Game-Changer for ASEAN Factories

HVE's Tool-Free 3D Printing for Rail Components: A Game-Changer for ASEAN Factories \\[BREAK] In a groundbreaking development, HÖRMANN Vehicle Engineering (HVE) and its research partners have successfully completed a 34-month project aimed at developing a tool-free, fully recyclable manufacturing process for large-format heavy-duty rail vehicle components. This innovative approach, known as the “3D-FiberTrain” project, has the potential to revolutionize the way rail components are produced, particularly in the ASEAN region. \\[BREAK] The project, funded by Germany’s Federal Ministry for Economic Affairs and Energy and the European Union, ran from September 2023 to June 2026. The team validated the technology by producing two demonstrator parts for Siemens Mobility’s ICE 3neo high-speed train: the nose section and front skirt. These components were chosen due to their demanding nature and the need for high precision and performance. \\[BREAK] The hybrid process developed by the consortium combines three key technologies into a single, seamless process chain. First, large-format, granule-based extrusion printing is used to create complex geometries without the need for expensive tooling. Next, a newly developed 3D tape-laying process applies continuous-fiber reinforcement to high-stress areas, following the component’s load path. Finally, automated milling ensures that the parts meet the required dimensional accuracy and surface quality. Because every stage of the process uses thermoplastic materials, the resulting components are fully recyclable, setting them apart from conventional thermoset composites. \\[BREAK] For ASEAN factories, this new process offers several advantages. In countries like Thailand, Vietnam, Indonesia, and Malaysia, where the rail industry is rapidly expanding, the ability to produce high-quality, fully recyclable components without the need for expensive tooling can significantly reduce production costs and lead times. Additionally, the flexibility to adapt designs and component variants without new tooling investment allows for greater innovation and customization, which is crucial in a competitive market. \\[BREAK] The 3D-FiberTrain project also aligns with the growing emphasis on sustainability in the ASEAN region. As more countries in the region commit to reducing their carbon footprint, the use of fully recyclable materials and more efficient manufacturing processes becomes increasingly important. This new technology not only reduces waste but also lowers the overall environmental impact of rail vehicle manufacturing. \\[BREAK] Furthermore, the success of the 3D-FiberTrain project paves the way for other additive manufacturing initiatives in the rail industry. For example, HVE is also involved in the LeiPo-3D-FKM project, which aims to bring metallic 3D printing into the FKM design guideline used across German engineering. This project, running from January 2025 to December 2027, is working to develop an additively manufactured steel alloy for FKM qualification and address factors like powder condition, AM system technology, and post-processing methods. \\[BREAK] The broader adoption of 3D printing in the rail industry is also being driven by the need for more sustainable and flexible manufacturing solutions. Rail operators and suppliers in the ASEAN region are increasingly turning to thermoplastic-based strategies to meet these demands. For instance, Stratasys has released a new flame-retardant, glass-fiber-reinforced nylon specifically for end-use rail production, developed in collaboration with Alstom and Siemens Mobility to meet EN 45545-2 fire safety standards. Similarly, Deutsche Bahn has certified Essentium’s flame-retardant thermoplastic materials for its High-Speed Extrusion 3D printer, which is now used to produce tens of thousands of replacement train parts. \\[BREAK] In conclusion, the 3D-FiberTrain project represents a significant step forward in the rail industry, offering a tool-free, fully recyclable manufacturing process that can benefit ASEAN factories. By reducing production costs, increasing flexibility, and promoting sustainability, this new technology has the potential to transform the way rail components are produced in the region. Factory buyers in ASEAN should consider adopting this innovative approach to stay competitive and meet the growing demand for sustainable and high-quality rail vehicles.