【3D Printing Application】Can 3D Printing Really 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 the "out with the old, in with the new" throwaway culture, Knorr Railway 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 big 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 corporation specializing in the manufacture of braking systems for railway and commercial vehicles. In recent years, it acquired the Danish DSB spare parts factory and invested in Nordic railway service operations.
Led by rapid prototyping manufacturing experts 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, it's commonplace to replace a slightly scratched iPad with a new one, but applying the same method to train production is clearly both expensive and unsustainable. Knorr Railway Systems manufactures new parts for all DSB (Danish National Railway Company) trains, repairs combustion heaters, extends the lifespan of internal components, and replaces safety and control equipment.
A Difficult Start
Lasse showcases the 3D printing laboratory he helped establish. He says, "When we first started working here, our 3D printing capabilities were almost non-existent. With some experience I gained from previous jobs, I quickly started printing useful things."
They moved from a single 3D printer on a workbench to a dedicated room with several Original Prusa 3D printers, all housed in Original Prusa enclosures. They primarily print with PETG, but occasionally use PC Blend — a stable environment makes printing with advanced materials much easier!
Clever Prints That Save Time and Money
When the Prusa team asked for examples of prints, Martin started to show off! He displayed various ingenious designs they had developed over the years: from relatively trivial handheld battery covers to improved fuel burner sensors.
The battery cover seems simple, but it's a crucial part, and new ones are no longer available. Even if you completely damage the terminal, Knorr Group employees can make 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 wears out over time. After that, you basically have to throw away the sensor and replace it with a new one. Printing the sensor housing with more durable filament extends the lifespan of the entire part while saving on replacement costs, halving the total cost. The same goes for motor gearboxes — a single printed part can save the cost of replacing an entire motor! Crazy, right?
Some 3D printed parts are more durable than injection-molded parts. Martin showed a typical example: the plastic part of an emergency handle. It requires a lot of force to pull, so it quickly wears out and breaks. 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. Therefore, Knorr Railway Systems introduced tamper-proof seals covering all screws. Compared to traditional injection-molded parts, this simple yet effective print saves even more time and money!
By the way, they are very strong. It took the Prusa team over ten minutes to film a few seconds of breaking the seal with a screwdriver.
Lasse admits, "From a broader perspective, we are still at the beginning, but hopefully, as 3D printing gains momentum across all industries, everything will accelerate."
"I see more and more people in the railway industry paying attention to 3D printing. It makes sense!" he says.
Long-term Users of Prusa 3D Printers
In Knorr Brake Systems' 3D printing lab, you'll find several Original Prusa MK3S+ printers, some of which are ancient MK3 machines purchased as early as 2017 and later upgraded to newer versions. These printers are true workhorses, running for thousands of hours with almost no maintenance.
There's also a brand new Original Prusa MK4 already in operation. Both Lasse and Martin love its print quality and auto-calibration features and look forward to trying out the quick-change nozzle function.
When asked what he liked most about 3D printing, Martin mentioned 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, not just in railways, but everywhere, adding, "Every technology has its limitations, but for 3D printing, I believe these limitations are not ultimate barriers but problems that will be solved sooner or later."
Related Products:
1) Prusa Original Prusa MK4 3D Printer
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