Deutsche Bahn (DB) is celebrating ten years of 3D printing, highlighting how the technology has moved from experimental use to a core pillar of its maintenance and supply chain strategy. Since 2015, the German rail operator has expanded its additive manufacturing ecosystem to more than 200,000 printed parts used across more than 1,000 applications, making it one of the most advanced rail-related AM programs in the world.
What began with simple plastic components has evolved into a wide portfolio of functional tools, interior fittings, electronic test rigs, and heavy-duty metal parts. Early success with basic items such as coat hooks encouraged DB to digitize more of its spare parts library, ultimately creating the Digital Warehouse, a central database that now contains over 1,000 component designs ready for on-demand production.
A 3D printed 540-kilogram gearbox housing that is used for DB’s shunting locomotives.
The range of printed parts illustrates how deeply the technology is integrated into DB’s operations. Maintenance teams regularly produce custom test fixtures, such as the printed circuit board testing assembly for ticket validators created by DB Kommunikationstechnik. They also manufacture handrail signs with braille, enabling rapid replacement of accessibility-related components without waiting for external suppliers. On the heavy-duty side, DB has successfully produced a 540-kilogram gearbox housing for shunting locomotives, demonstrating that large structural components can also be manufactured additively when conventional supply chains fall short.
These parts are printed using a variety of processes. Powder bed fusion is used for intricate polymer parts with detailed geometries, while large metal components are produced through wire or powder-based processes. Material extrusion also plays a role in creating tools and fixtures, especially when DB tests alternative materials. Several depots are experimenting with recycled filaments, including plastic derived from discarded ski boots, to further reduce the environmental impact of production.
DB also began 3D printing handrail signs with braille to help replace and install new accessibility-related components in stations.
A major strength of DB’s approach is its ability to produce parts exactly when they are needed. This eliminates the cost and space required for stocking slow-moving spares and significantly shortens repair timelines. In cases where manufacturers have discontinued older components, 3D printing provides a pathway to keep aging trains in service rather than retiring them prematurely.
DB has also built a nationwide recycling system for 3D printing waste. Working with partners, the company collects unused prints, failed prototypes, and other scrap material from sites across Germany. These are shredded, converted into granules, and then extruded back into new filament on reusable spools. The closed-loop process keeps materials in circulation and strengthens DB’s sustainability goals.
A 3D printed circuit board for ticket validators was created by the DB Kommunikationstechnik.
Additive manufacturing is now taught across DB’s vocational training programs, giving apprentices hands-on experience with design and production tools. The company also encourages internal innovation through an annual competition that has produced creative applications such as camera covers, tanking tools for ICE trains, and furniture made from recycled concrete.
A decade into its additive journey, DB shows no signs of slowing down. With digital models ready for instant production, recycled materials entering circulation, and more than 1,000 proven use cases, 3D printing is now a strategic asset for Germany’s rail network. The technology supports faster repairs, reduces manufacturing waste, and offers a lifeline for parts that no longer exist in traditional supply chains.
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*All Photo Credits: Deutsche Bahn (DB)