[3D Printing Application] Can 3D Printing Be Used to Repair Trains? Knorr Group Confirms the News!
Knorr Group: Repairing Trains with 3D Printing and Self-Extinguishing Filaments
In an era dominated by a throwaway culture of replacing old with new, Knorr Bremse Rail Systems Denmark offers a refreshing approach, repairing trains by making the most of every component. When necessary, they design and manufacture new parts 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. All aboard! Innovation has just begun!
[Note]: Knorr Group is a German multinational company specializing in the manufacture of braking systems for railway and commercial vehicles. In recent years, it acquired DSB's parts factory in Denmark and invested in Nordic railway service operations.
Led by rapid prototyping specialists Lasse Dampe Hardö and Martin Einsberg Nihøj, the Prusa team delved directly into the realities of train production: finding ways to repair or replace parts that are no longer available to reduce scrap rates. Today, replacing a slightly scratched iPad with a new one is commonplace, but applying the same method to train production is clearly expensive and unsustainable. Knorr Bremse Rail Systems manufactures new parts for all DSB (Danish State Railways) trains, repairs combustion heaters, extends the lifespan of internal components, and replaces safety and control equipment.
A Difficult Start
Lasse showcases the 3D printing lab he helped establish. He says, "When I started working here, our 3D printing capabilities were almost non-existent. With some experience accumulated from my previous job, I quickly started printing useful things."
They moved from a single 3D printer on a workbench to a dedicated room filled with several Original Prusa 3D printers, all housed in Original Prusa enclosures. They primarily print with PETG, but sometimes also use PC Blend — with a stable environment, printing with advanced materials becomes much easier!
Clever Prints Saving Time and Money
When the Prusa team asked for examples of prints, Martin eagerly showed off! He demonstrated various clever designs they had developed over the years: from relatively trivial handheld battery covers to improved fuel burner sensors.
The battery cover, though seemingly simple, is a crucial part and is no longer available off the shelf. Even if you completely damage the terminal, Knorr Group employees can manufacture a new one for you. They used 3D printing to create a chassis prototype and an SLS printer to produce a new, durable metal chassis.
The fuel burner sensor is a prime example of clever and sustainable thinking: the entire sensor is held together by a plastic part that gradually wears down over time. After that, you'd essentially have to throw away the sensor and replace it with a new one. Printing the sensor housing with a more durable filament extends the lifespan of the entire part while saving replacement costs, halving the total cost. The same applies to the motor gearbox — one printed part can save the cost of replacing the entire motor! Crazy, right?
Some 3D printed parts are more durable than injection molded parts. Martin demonstrates a typical example: the plastic part of an emergency handle. It requires a lot of force to pull, so it wears out and breaks quickly. A simple printed part can better withstand the pressure and keep the entire device intact.
Last but not least, Martin proudly showed the Prusa team the Automatic Train Control system (ATC) — essentially, a metal box installed on the tracks every few hundred meters. It plays a very important role: helping drivers and dispatchers monitor the train's position. Ensuring its safety and preventing unauthorized manipulation is crucial. Therefore, Knorr Bremse Rail Systems introduced tamper-proof seals covering all screws. This simple and effective print saves more time and money compared to traditional injection-molded parts!
By the way, they are incredibly strong. The Prusa team spent over ten minutes trying to capture a few seconds of footage of the seal being broken with a screwdriver.
Lasse admits, "From a broader perspective, we are still at the beginning, but we hope that as 3D printing technology gains momentum across various industries, everything will eventually accelerate."
"I see more and more people in the railway industry focusing on 3D printing. It makes sense!" he says.
Long-time User of Prusa 3D Printers
In Knorr Bremse's 3D printing lab, you'll find several Original Prusa MK3S+ printers, some of which are vintage MK3 machines purchased as early as 2017 and later upgraded to newer versions. These printers are true workhorses, boasting thousands of hours of printing time with minimal maintenance.
There's also a brand new Original Prusa MK4 already in operation. Both Lasse and Martin appreciate its print quality and automatic calibration features, and they look forward to trying out the quick-change nozzle function.
When asked what he likes most about 3D printing technology, Martin cited rapid production, sustainability, and shorter lead times, saying it's the best tool for repairing and designing parts.
Lasse believes we should expect to see more 3D printing technology, not just in railways, but everywhere, adding, "Every technology has its limitations, but for 3D printing technology, I don't see these limitations as ultimate barriers, but rather as problems that will be solved sooner or later."
Related Products:
1) Prusa Original Prusa MK4 3D Printer
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