[3D Printing Applications] 3D printing can actually be used to repair trains? Knorr-Bremse Group has confirmed this news!
Knorr-Bremse Group: Repairing Trains Using 3D Printing and Self-Extinguishing Wire
In an era rife with a culture of discarding old for new, Knorr- Bremse 's approach is refreshing . They utilize every component in train maintenance , designing and manufacturing new parts when necessary using Prusa 3D printers and printing materials (self-extinguishing Prusament PETG V0 filament) . This is not only a significant step towards sustainability but also a perfect demonstration of the possibilities of additive manufacturing. Hop on board, the innovation has just begun!
[Note]: Knorr-Bremse is a German multinational company specializing in the manufacture of braking systems for railways and commercial vehicles. In recent years, it has acquired the Danish DSB parts factory and invested in Nordic rail services .
Led by rapid prototyping manufacturing experts Lasse Dampe Hardö and Martin Einsberg Nihøj, the Prusa team went straight into the realities of train production: reducing scrap rates by finding ways to repair or replace unusable parts. Today, replacing a slightly scratched iPad with a new one is commonplace, but using the same method to produce trains would be both expensive and unsustainable. Knorr- Bremse Systems manufactures new parts for all DSB (Danish National Railways) trains, repairs combustion heaters, extends the lifespan of internal components, and replaces safety and control equipment.
A difficult start
Lasse showed off the 3D printing lab he helped set up. He said, "When I first started working here, our 3D printing technology was practically zero. Leveraging some experience I had gained in my previous work, we quickly started printing some useful things."
They moved a 3D printer from their workbench to a dedicated room containing several Original Prusa 3D printers , all housed in Original Prusa chassis. They primarily use PETG printing, but sometimes also PC Blend printing—a stable environment makes printing with advanced materials much easier!
Clever printing that saves time and money
When the Prusa team wanted some examples of prints, Martin stepped up! He showcased a variety of ingenious designs they had developed over the years: from the relatively trivial handheld battery cover to the improved fuel burner sensor.
The battery cover may seem simple, but it's a crucial component, and there are no more readily available replacements. Even if you damage the entire terminal, Knorr-Bremse employees can build you a new one. They created a chassis prototype using 3D printing technology and then fabricated a new, durable metal chassis using an SLS printer .
The fuel combustion sensor is a prime example of ingenious and sustainable thinking: the entire sensor is held together by a single plastic part, which wears down over time. Eventually, the sensor essentially has to be discarded and replaced. Using more durable wire to print the sensor housing extends the lifespan of the entire component, saving on replacement costs and cutting the total cost in half . The same applies to motor gearboxes—a single printed part can save the cost of replacing the entire motor! Insane, right?
Some 3D-printed parts are more durable than injection-molded parts. Martin demonstrates a typical example: the plastic parts of an emergency handle. It takes a lot of force to pull it, so it wears out and breaks quickly , while a simple printed part can withstand the pressure better and keep the entire device intact .
Last but not least, Martin proudly presented the Automatic Train Control (ATC) system to the Prusa team—essentially a metal box installed every few hundred meters along the tracks. It plays a crucial role: helping drivers and dispatchers monitor train positions , ensuring their safety, and preventing unauthorized manipulation. Therefore, Knorr-Bremse Railway Systems introduced tamper-proof seals covering all screws , a simple and effective print that saves significantly more time and money compared to traditional injection-molded parts!
By the way, they are very sturdy. It took Prusa's team more than ten minutes to film a few seconds of footage of breaking the seal with a screwdriver.
Lasse acknowledged, "From a broader perspective, we are still in the early stages, but hopefully things will accelerate as 3D printing technology gains momentum across various industries."
"I'm seeing more and more people in the railway industry paying attention to 3D printing technology. And that makes sense!" he said.
Long-term user of Prusa 3D printers
In Knorr Brake Systems' 3D printing lab, you'll find several Original Prusa MK3S+ printers, some of which are older MK3 machines purchased back in 2017 and later upgraded to newer versions. These printers are true powerhouses, printing thousands of hours with virtually no maintenance required.
A brand new Original Prusa MK4 is already in operation. Lasse and Martin both like its print quality and automatic calibration function, and are looking forward to trying out the quick-change nozzle feature.
When asked what he liked most about 3D printing technology, Martin mentioned rapid production, sustainability, and shorter delivery times , saying it was the best tool for repairing and designing parts.
Lasse believes we should expect to see more 3D printing technology, not just on railroads, but everywhere. He added, "Every technology has its limitations, but for 3D printing, I don't think these limitations are the ultimate obstacle, but rather problems that will be solved sooner or later."
Related products:
1) Prusa Original Prusa MK4 3D Printer
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