AM with Ultrasint® PA11 Improves Worker Health and Safety at Ekyrail Enterprises

Durable, custom-fit protective covers with complex geometries by Solaxis

To manage the electric current and consequently ensure various driving-related functions, locomotives are equipped with switches. However, this equipment can present health and safety issues for rail industry professionals who handle them.

Project Breakdown

Industry & Application
Electronics/Transport

Product
Ultrasint® PA11

Partner & Technology
Printing Service: Solaxis
Selected Machine Manufacturer: Farsoon

Why Forward AM?

  • Excellent mechanical properties
  • Durability
  • End-use quality

Key Results

  • Flexible processes for complex designs
  • Mechanical strength
  • Chemical resistance
  • Quality surface finish

The Challenge

Producing a custom, complex-shaped protective cover for an electrical switch, with a short lead time to support health and safety measures

 

To choose the best manufacturing approach, the team at Solaxis, the 3D printing service behind this project, had  address several key requirements:

  • Quick turnaround: Rapid production to meet immediate safety needs.
  • Complex geometry: The part’s intricate design, with cavities and reinforcements, makes traditional machining challenging and costly due to limited internal access and precision demands.
  • Low-volume production: With an initial order of around 100 parts per year, the high upfront costs of molds or tooling weren’t justified.
  • On-demand batch availability: Small batches are required to match the gradual development pace in the railway sector, ensuring spare parts are readily available as needed.
  • High durability and quality: The final part must withstand frequent handling and meet end-use standards for robustness and finish.

The Solution

Solaxis figured that Selective Laser Sintering (SLS) with Ultrasint® PA11, addressed these needs effectively, enabling the production of complex, durable parts without high tooling costs, ideal for low-volume and customizable manufacturing. Here’s why:

Complex Geometry: AM allowed for the precise creation of complex shapes, such as the cover’s intricate cavities and reinforcements, without the limitations of traditional machining.

Low-Volume Cost Efficiency: With around 100 parts needed per year, AM avoided the high upfront costs of molds or tooling, making it cost-effective for small production runs.

Rapid Turnaround: AM enabled quick production of parts to meet urgent safety requirements, supporting Ekyrail’s need for short lead times.

Flexibility in Design: Since AM doesn’t require retooling, it allows for easy adjustments to the part’s design, supporting iterative improvements as the product evolves.

Durability and Surface Finish: Materials like Ultrasint® PA11 provided the necessary mechanical strength and quality finish, meeting the durability standards required for frequently handled, end-use safety parts.

Next Steps

Reference Links and Documents

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