The novelty is the process chain.
After 34 months, HÖRMANN Vehicle Engineering (HVE) and its consortium partners have completed 3D-FiberTrain. The research project targets tool-free production of large-format, heavily loaded outer skin components for rail vehicles.
The engineering company specializing in the development process chain of rail, road, and special vehicles chose as demonstrators the nose and front skirt of Siemens Mobility’s Velaro MultiSystem high-speed train (the ICE 3neo, Class 408), a platform rated for operating speeds up to 320 km/h.
Those components are currently produced using thermoset fiber-reinforced composites, via hand lay-up or vacuum infusion. According to HVE, these processes face familiar constraints: high tooling costs, long production times and heavy manual labor. Their materials are also difficult to recycle.
A three-stage manufacturing chain
The consortium’s alternative combines three stages:
- Granulate-fed large-format extrusion prints the complex geometry without dedicated molds.
- A newly developed 3D tape-laying process then adds continuous fiber reinforcement along load paths, targeting high-stress areas only.
- Automated milling closes the chain, delivering dimensional accuracy and surface quality.
Since the chain is entirely thermoplastic, the consortium states it is fully recyclable.
HVE led the project and defined requirements, design specification and structural validation. It worked with Fraunhofer IWU (Upper Lusatia Plastics Center, Zittau), Fraunhofer IMWS (Schkopau), Lakowa GmbH (Wilthen), and Siemens Mobility as associated partner.
The project ran from September 2023 to June 2026 under grant 19I23008A. The German Federal Ministry for Economic Affairs and Energy funded it with EU support. HVE reports lower manufacturing costs for small and medium series, shorter lead times, a reduced carbon footprint and faster design iteration.
Demonstrators in an established field
A number of exterior rail parts have already been additively manufactured. As we reported in 2020, Siemens Mobility was already printing front casing parts for streetcars through its Easy Sparovation program, while DB ESG and Angel Trains trialled ULTEM 9085 interior parts on UK passenger trains.
Since then, we have witnessed other applications and developments made specifically for this field: Eplus3D braking discs (2022), SABIC’s rail-compliant materials (2022), and Hitachi Rail’s spare parts work with Roboze (2024).
Alongside the other applications in the field, the combination of extrusion, continuous-fiber reinforcement and machining developed in 3D-FiberTrain makes the case for a hybrid manufacturing approach in the railway industry.
That said, rail exterior parts must satisfy the applicable fire-safety and structural requirements. The announcement establishes a validated process chain and demonstrator components, rather than approval for passenger service.
Images: Fraunhofer IWU, HÖRMANN Vehicle Engineering GmbH
Source: HÖRMANN Vehicle Engineering — 21 July 2026.
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