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3D-printed 1:5 nose mock-up for Alstom image

The collaboration with Alstom involved Caracol in the creation of a 3D-printed mock-up of a train nose for the AGV Italo train (Italian high-speed train). This mock-up, built at a 1:5 scale, aimed to streamline the design phases through a geometrical fit check, ensuring quicker iterations and reducing the risk of errors in later production stages.

Key insights

  • Design optimization: the mock-up was designed to quickly validate the fit and design of the train nose, allowing Alstom’s team to catch potential issues early in the development process. This proved to be invaluable for accelerating the design and manufacturing timelines.
  • Lightweight and portable mockup: the 1:5 scale was chosen not only to facilitate the design and validation process but also to make the mock-up easily portable for events and presentations. The mock-up is often used in promotional and client-facing activities, including exhibitions such as the EXPO Ferroviaria in Milan and InnoTrans in Berlin.

Printing specifications

  • System: Heron 300
  • Extruder: High Accuracy (HA)
  • Nozzle size: 3 mm
  • Material: ABS + 30% GF
  • Printing Time: 25 hrs
  • Weight: 30 kg
  • Size: 1000 x 1400 x 1450 mm

Benefits

  • Lead time reduction: up to 60 %
  • Waste reduction: 60%
  • Cost reduction: up to 40%

Conclusion

The collaboration between Alstom and Caracol highlights the transformative power of robotic LFAM in the railways industry. By leveraging advanced 3D printing technology, the project not only accelerated design validation but also enhanced flexibility and efficiency in prototyping processes. The creation of the 1:5 scale train nose mock-up showcases how innovation can drive more sustainable, precise, and cost-effective manufacturing solutions, setting a new benchmark for future projects in the railway sector.

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