By Melissa Donovan
Prototyping is a common use of three-dimensional (3D) printing technologies. When we think prototype, we often imagine a part on the smaller scale, but thanks to large format 3D printers prototypes can be larger than life. The result is an accurate representation of the final piece in appearance as well as size.
Express Train
Alstom is a world leader in integrated transport systems; developing and marketing equipment and services for this sector. A complete range of solutions is available from the provider—high-speed trains, metros, tramways, e-buses, customized services, infrastructure, signaling, and digital mobility systems.
One of the company’s customers is Amtrak—the well-known high-speed rail operator in the U.S. Together, the two institutions partnered in 2019 to introduce the next generation of the Acela. The Acela is Amtrak’s flagship express service along the Northeast Corridor in the Northeastern U.S. between Washington, D.C. and Boston via 14 intermediate stops, including Baltimore, Philadelphia, and New York City.
With the goal of redefining the customer experience, Alstrom is currently in the process of designing and building a new, state-of-the-art Acela fleet. The goal is to deliver the first of 28 trainsets beginning in 2021. They feature high-speed service, modern amenities, and close to 25 percent more seats.
Starting the redesign with the power car—the first car in a trainset and the driver’s station—when creating the prototype, Alstrom reached out to 3D Platform. Based in France, Alstrom already owned a printer from 3D Platform, but didn’t think it could print all of the material in the amount of time it needed to be completed. In talking with 3D Platform, the decision was made for the printer manufacturer to print all of the parts at its headquarters in IL.
For the Amtrak power car prototype, Alstrom required 3D printed panels for integration into the full-scale mockup of the driver desk and cabin lining. 3D Platform was tasked with providing Alstrom with nine printed panels that would be ready for painting when delivered to the customer—all completed in a short time frame.
3D Platform relied on the large format build area of its multiple WorkSeries printers, at one point there were ten running at once. The 200, 300, and 400 models were all used.
The 200 Series Workbench Classic large scale 3D printer features automatic-mesh bed leveling, SurePrint Step-Servo hybrid motors, and duel electronics with remote operating and monitoring capabilities. Its print volume is 1,000×1,200×500 millimeters (mm).
The 300 Series WorkbenchPro is a fused filament fabrication additive manufacturing system with a large 1x1x0.7-meter build area. With SIMO Series actuators and Constant Force anti-backlash lead screws and nuts, the WorkbenchPro provides a rugged, industrial framework. Additionally, it delivers 40 percent more build volume and up to 16 times faster print rates with its unique features.
400 Series Workbench Xtreme is the only large scale 3D printer engineered from the ground up. Most importantly, the unique, parametric design are easily adjusted to match the needs of the customer. Its print volume is 1,000×1,500×700 mm.
Despite the large work area offered by the WorkSeries printers, the panels were so large—some over two meters in width, they had to be printed in sections and glued together. Some of the panels could have been printed in one piece, but breaking them into multiple components eliminated a large amount of support material. In total, 21 sections were printed to create the nine parts.
The window frames of the cab were printed on the WorkSeries 400 machines. The rest of the parts were printed in halves using a combination of the WorkSeries 200 and 300, and then glued together. The driver’s station was printed in seven pieces and then also glued together.
After printing, the panels’ surfaces were prepped for painting. 3D Platform used Smooth-On or Evercoat automotive putty to fill, sand, and prime. All of the panels were delivered on time to Alstrom.
Life Size
With short deadlines companies have to weigh their options and leverage unique partnerships with their providers. In this case, Alstrom turned to 3D Platform to create a prototype of the engine cabin for Amtrak’s newest Acela trainset. The result was a life-size model that truly showcases the ingenuity of 3D printing.
Apr2020, Industrial Print Magazine