PSI - Issue 53

Vítor M.G. Gomes et al. / Procedia Structural Integrity 53 (2024) 285–290 Author name / Structural Integrity Procedia 00 (2023) 000–000

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certification illustrated in Fig. 2 - B and Fig. 2 - C. A few years ago, CAF manufacturing company developed the first light train integrating a series of additively-manufactured front-end components as shown in Fig. 2 - D. In the production of these components, advanced polymers were used (AMFG (2019)).

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Fig. 2. A - AMmed pull-out box shell (Railway International (2022)), B - AMmed cable guides (KIMYA (2021)), C - Application of AMmed cable guides (KIMYA (2021)), D - Front-end of a tram produced by additive manufacturing process, (AMFG (2019)); E - AMmed parts produced by fused deposition modelling (AMFG (2019)); F - Prototype of a seat for train manufactured by AM, (Madeleine (2022)). With respect to the interior of the train, AM has been also employed in the development of some components printed by fused deposition modelling, FDM, such as folding shelves, handles, armrests, and seats (see Fig. 2 - E) (AMFG (2019)). In the development of seats, the manufacturer states that joining AM process allowed to reduce in 90% the cost production (see Fig. 2 - F). Additionally, by optimizing the manufacturing process of these seats, the manufacturer reduced the time of manufacturing and assembling process by around five times (Madeleine (2022)). Other examples of AM applications are roll stops for railway carriages (VoxelMatters (2020)) and wheel-set bearing covers (AMFG (2019)). In the last example, the application of Wire Arc Additive Manufacturing technology allowed a reduction in production costs and production time of around 30%.

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Fig. 3. A - Roll stops for railway carriages produced by AM with milling finishing (VoxelMatters (2020)), B - Near-net-shape wheel-set bearing cover (left) and a post-machined part (right) (AMFG (2019)).

A 3D-printed near-net-shape wheelset bearing cover