Spare Part Management / Services

Single Part Production

You need a spare part for your rail vehicle, but

  1. it is only a single part?
  2. it is a component for which the original manufacturer no longer supplies spare parts?
  3. it belongs to a project that we have not produced for a while now?

This is part of our daily business. We use our entire knowhow and experience to ensure that everything runs smoothly again for you soon. For this we take over the entire process:

  • Search for new suppliers
  • Any design adjustments
  • Production of the required components

When manufacturing spare parts that are no longer available, we use modern processes to keep the incurred costs as low as possible and to be able to react flexibly. This includes:

  • Creation of CAD data for the production of spare parts
  • Production of new moulding tools & models
  • Single part production through additive manufacturing processes (3D printing: rapid manufacturing / direct manufacturing)

WE ARE HAPPY TO HELP YOU

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3D Printing

Additive manufacturing is an innovative and futureoriented process which enables us to convert virtual 3D models into physical objetcts in the shortest possible time and on demand. 3D printing is divided into three categories:

the production of Rapid Prototyping

= the construction of prototypes to quickly assess whether a concept is suitable for serial production.

the production of Rapid Tooling

= the construction of tools, molds and fixtures in order to be able to implement quick one off productions or very small batches. As you purchase the tools for custommade products, you directly benefit from the low manufacturing costs of 3D printing compared to conventional manufacturing methods.

the production of Rapid Manufacturing / Direct Manufacturing

= the construction of individual parts, which are subsequently processed in series or as spare parts. For higher volumes, there are more costeffective systems, but for small batches or oneoffs, the additive manufacturing is the most flexible and costeffective solution. The finished components are then painted with the robust paints used in series production, so that the new component blends seamlessly into the overall look.

In additive manufacturing both filament and granulatebased thermoplastic compounds are used. The material is applied layer by layer according to the computercontrolled specifications of the CAD data.

Smallscale additive manufacturing (filament based)

Manufacturing and assembly jigs

  • Customized painting template
  • Drilling jigs
  • Positioning jigs

Components

  • Production of obsolescent components
  • Spare parts
  • Small batches

Materials: PLA, PETG, PETG-CF, ABS, ASA, PP, PA, PA-CF, PC-CF, TPU
Print volume: 250 mm x 210 mm x 400 mm

Largescale additive manufacturing using robotic technology (granulate based)

  • Large objects made from thermoplastic compounds
  • Jig and fixture construction
  • Mold construction
  • Production of large components
  • Subsequent milling of functional surfaces possible

Materials: PP-, PET-, PA-, PC-, ASA-, PPS-Compounds (more possible)

output: up to 15 kg/h

Print bed size: 4m x 2m

Print volume: Depending on the component geometry

DAMAGE INSPECTION

Nondestructive testing (NDT)/ thermography

Thermographic testing allows the evaluation of the internal structure of fiber-reinforced components (GFRP, CFRP, etc.) without damaging or disassembling the components that need to be tested. This is done by heat flows that are conducted through the component. The distribution of the heat is measured with sensors in a contactless manner. Based on the measurement results, conclusions can subsequently be drawn about the quality and structure of the component.

Areas of application:

  • During production of system components: Inspection in quality assurance to detect hidden defects (before delivery).
  • During regular maintenance: for early detection of cracks and minor damages.
  • For general assessment of the condition of the fiber-reinforced component with regard to further lifetime/ lifetime extensions.
  • For damage-assessment to the components involved in an accident before preparing the cost estimate. Thermography is particularly helpful if no visible damage has occurred in the first step (e.g. in the case of an electrical flashover caused by contact between the front mask and the overhead line).
  • To prove any water retention or its effects.

Advantages:

  • Digitally available documentation and proof of condition / quality of fiber-reinforced components
  • Ensuring the highest quality standards
  • Examination of crashed or damaged structures in assembled condition
  • Direct derivation of necessary repair work with three possi-ble outcomes:
    a) no GRP damage present
    b) Spot repair possible
    c) Component replacement required

Application Example Thermography

Application Example Thermography The front mask of the train was damaged in a crash. Using thermography, we examination, we determined how extensive the damage is. Based on the provided data, it became clear that a partial repair (spot repair) is possible and not that, as feared, the entire component has to be replaced.

Step 1:
Findings
Step 2:
Damage containment
Step 3:
Spot repair is done

Advantages:

  • huge time savings: approx. 4 months for testing and implementation of the repair (for comparison: the pure delivery time for a replacement front mask without installation is at least 6 months)
  • significant cost savings