Sand Dispenser - Challenge

The DB Group (Deutsche Bahn) is one of the world's leading mobility and logistics companies and employs some 331,600 people around the globe. The DB Group designs and operates the transport networks of the future. Through the integrated operation of traffic and railway infrastructure as well as the economically and ecologically intelligent connection of all modes of transport, the DB Group moves people and goods.

When the manufacturer of the left-side sandbox housing - a part of the brake system - has ceased its production, Deutsche Bahn got into trouble because a failure of the sand dispenser leads directly to a downtime of the locomotive which immediately causes immense downtime costs. Since the original component was manufactured as grey cast iron, the purchasing department tried in vain to find alternative suppliers which made the sand dispenser a critical part.

Sand Dispenser - Challenge
Sand Dispenser - FIT Solution

Sand Dispenser - FIT Solution

S.P.O.D. (Spare Parts on Demand)

Feasibility check
Result: Manufacturing of the sand dispenser with the previously used material and production technology is not possible. Additive manufacturing needs a design adjustment of the component and a new process for its manufacturing. 

Feasibility study
- Recommended material: Titanium
- Recommended technology: Electron Beam Melting (EBM)

Design adjustment

AM-optimized design adjustment (wall thickness etc.) according to the selected AM technology and considering the high requirements of this particular spare part

ADM-Q

Additive manufacturing with our highly standardized AM process for Electron Beam Melting (EBM) of end-use parts

Finishing

- Support removal
- Blasting
- Milling

Quality assurance

- CT scan after manufacturing
- Qualification from Deutsche Bahn successfully completed by performing a blasting test to ensure wear resistance


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