Pneumatic braking systems play a vital role in rail transport, including subways, trams, and other rail vehicles. Traditionally, brake panels were assembled from several metal parts, which caused issues such as heavy weight, potential pneumatic leaks, and challenges in design customization.

To overcome these challenges, Wabtec, a leading manufacturer of rail braking systems that provides equipment, systems, and digital solutions, has adopted additive manufacturing technology, specifically the Nikon SLM Solutions 3D metal printer, to produce lighter, more efficient, and easily customizable brake panels.

Additive Manufacturing in the Rail Industry

3D printing technology, especially laser powder bed fusion (LPBF) using SLM 3D printers, is transforming how components are produced in the rail industry. For Wabtec, this technology opens new possibilities for designing and manufacturing pneumatic brake systems for subways and other rail vehicles.

While the rail sector has been slower to adopt metal additive manufacturing (AM) compared to industries like aerospace, the rail industry presents significant potential for AM applications. Whereas aerospace often focuses on fuel-moving engine components, rail systems primarily involve pneumatic parts, making them ideal for this technology.

Additive manufacturing not only reduces costs but also optimizes the production process by decreasing the number of parts that need to be assembled and facilitating the customization required for various global transit systems.

3D Printed Brake Panel – Optimized Solution with SLM Metal 3D Printers

The pneumatic brake panel is produced from aluminum alloy using SLM 3D metal printing technology. Previously, brake panels consisted of six separate parts that were machined and assembled, but with the SLM 3D printer, the entire panel is printed as one single piece. This reduces the panel's weight from 14kg to just 2.8kg and allows for easy design customization.

3D Printed Rail Brake Panel Image

By using SLM 3D printing, Wabtec can quickly change the design without needing to modify tools or the production process. This flexibility is crucial since every transportation system has unique technical requirements and regulations, necessitating brake panel customization.

Benefits of Additive Manufacturing with SLM Metal 3D Printer

- Easy Customization: 3D printing technology allows for rapid design changes digitally, eliminating the need for altering tools or manufacturing processes, as in traditional methods.

- Time and Cost Savings: Manufacturing time and costs are reduced by decreasing the number of parts and simplifying the assembly process.

- Weight Reduction: The lighter brake panel is easier to transport, install, and replace, increasing operational efficiency.

Wabtec's Brake Panel Production with SLM 3D Printer

The SLM 800 3D printer is used at Wabtec’s Neighborhood 91 facility in Pittsburgh to print brake panels. Equipped with four lasers and a build volume of 500 x 280 x 850 mm, this LPBF platform is designed for high-speed printing on a large scale. The machine can print eight brake panels simultaneously in approximately 100 hours. While the printing time might seem long, compared to traditional manufacturing, 3D printing significantly reduces time and machining steps.

Bulk Metal 3D Printing of Brake Panels with SLM 800 Image

The SLM 800 is integrated with the SLM Hub, which combines three interchangeable build boxes, pre-heating stations, automatic depowdering, material recovery, and a permanent filter module. This closed-loop system minimizes human interaction with metal powders and simplifies processes like powder handling and recycling.

Machine SLM 800 Connected with SLM HUB Image

The brake panels are 3D printed using an aluminum alloy, a popular material in additive manufacturing for its lightweight, durable, and machinable properties. In this process, Carpenter Additive not only supplies metal powder but also offers software and hardware solutions, like the PowderLife system, to manage powder, ensuring quality and minimizing waste.

PowderLife efficiently monitors, stores, and distributes metal powder, ensuring material quality and reducing waste.

Materials used for 3D printing:

ALL ABOUT 3D PRINTING MATERIALS: METAL AND CERAMICS

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Metal powder at Wabtec Neighborhood 91

After printing, the brake panels go through post-processing steps, including powder cleaning at the fully enclosed automatic depowdering station of the SLM Hub, and additional machining of critical surfaces. This ensures that important details like mounting surfaces and pneumatic connections meet high-quality standards.

A notable point is that the entire production process, from 3D printing to post-processing and machining, is carried out at the same facility. This allows Wabtec to maintain strict control over product quality and optimize the production workflow.

SLM HUB's self-contained automatic de-powdering system

Learn more: Post-Processing Metal 3D Printed Parts: Procedures and Key Considerations

Comprehensive Benefits from the SLM 3D Printer

Using the SLM 3D printer has allowed Wabtec to simplify both the assembly and machining processes while drastically reducing the weight of the final product. Traditional brake panels weighed up to 14kg, but thanks to metal 3D printing, the new panels are just 2.8kg, making transportation, installation, and replacement much easier. Integrating tubes and connectors directly into the 3D-printed part also streamlines assembly and cuts costs.

The SLM 800 offers an extended z-axis for producing large-scale parts and enables the connection of multiple machines via the SLM Hub, opening new possibilities for large-scale industrial metal additive manufacturing.

Impact of SLM Technology on the Rail Industry

The SLM 3D printer not only brings production advantages for brake panels but also drives positive changes across the rail industry. By switching to 3D printing, Wabtec can optimize its production processes and enhance product customization for various rail systems worldwide. The 3D-printed products are lighter, easier to install, and maintain, while also being more reliable for braking systems.

Additive manufacturing technology, particularly with SLM 3D printers, is set to expand further in the rail sector. With rapid customization and mass production capabilities, Wabtec is pioneering the application of this technology across a variety of other rail components.

Learn more about related case studies:

SLM 280 Metal 3D Printer: A New Leap in Australian Aerospace

INCREASE 4 TIMES THE EFFICIENCY OF HEAT EXCHANGER FOR HELICOPTER WITH GYROID STRUCTURE

Conclusion

Metal 3D printing technology, especially using SLM 3D printers, is revolutionizing the production of pneumatic brake panels at Wabtec. This transformation simplifies manufacturing processes, reduces costs, enhances customization, and unlocks new potential for producing rail components. With the efficiency and reliability provided by 3D printing, this technology is poised to continue evolving and shaping the future of manufacturing.

Reference: INCREASE 4 TIMES THE EFFICIENCY OF HEAT EXCHANGER FOR HELICOPTER WITH GYROID STRUCTURE

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