HÖRMANN Develops 3D-Printed Rail Component Process Chain
HÖRMANN Vehicle Engineering GmbH creates a novel 3D printing process for rail vehicle components, aiming to reduce costs and improve sustainability.
HÖRMANN Vehicle Engineering GmbH (HVE) has developed a 'completely novel process chain' for 3D printing large-format outer skin components for rail vehicles. The project, called 3D-FiberTrain, was funded by the Federal Ministry for Economic Affairs and Energy and ran from September 2023 to June 2026. The initiative aimed to create an innovative, tool-free manufacturing process for heavy-duty rail components.
Traditional methods for producing large-format outer skin components involve thermoset-based fibre-reinforced composites, which are costly and labor-intensive. HVE and its partners developed a process combining granule-based 3D printing, a newly developed 3D tape-laying technique, and automated milling. This approach uses thermoplastic materials, enabling full recyclability and reducing manufacturing time and costs.
The process was tested on the Velaro MultiSystem high-speed train (ICE 3neo, Class 408), with the nose and front skirt being manufactured to validate the technology. The consortium reported reduced carbon footprint and faster design iterations, making the process ideal for small and medium production runs.
This process chain represents a significant advancement in additive manufacturing for rail applications. By eliminating tooling and using recyclable thermoplastics, HVE’s method aligns with industry trends toward sustainable, flexible production. The technology could influence broader adoption of 3D printing in transportation, particularly in sectors requiring complex, durable components.
Edited by the news editor with AI from the original report — please refer to the original source.