HVE Completes Tool-Free 3D Printing Process for Rail Components
HVE and partners develop a recyclable, tool-free 3D printing process for rail vehicle parts, aiming to reduce costs and environmental impact.
HÖRMANN Vehicle Engineering (HVE) and its research partners have completed a 34-month project to develop a tool-free, fully recyclable manufacturing process for large-format rail components. The initiative, called 3D-FiberTrain, was funded by Germany’s Federal Ministry for Economic Affairs and Energy and the European Union, running from September 2023 to June 2026.
The project’s hybrid process uses thermoplastics and combines granule-based extrusion printing, 3D tape-laying for fiber reinforcement, and automated milling to produce high-stress rail components. This approach eliminates the need for expensive tooling and allows for greater design flexibility and recyclability. The team validated the technology by creating demonstrator parts for Siemens Mobility’s ICE 3neo high-speed train, including the nose section and front skirt.
HVE reported that the process reduces manufacturing costs, shortens production times, and lowers the carbon footprint through efficient material use. The project also highlights a shift toward sustainable rail manufacturing, with HVE working on additional additive manufacturing initiatives, such as LeiPo-3D-FKM, which explores metallic 3D printing for engineering standards.
HVE’s tool-free 3D printing process addresses key sustainability and cost challenges in rail manufacturing by using recyclable thermoplastics. This aligns with broader efforts in additive manufacturing to reduce waste and improve material efficiency, particularly in high-performance applications like high-speed rail.
Edited by the news editor with AI from the original report — please refer to the original source.