Chemnitz, July 2026 – After 34 months of intensive research, HÖRMANN Vehicle Engineering GmbH (HVE), together with its project partners, has successfully completed the “3D-FiberTrain” collaborative project. The goal of the project, funded by the Federal Ministry for Economic Affairs and Energy, was to develop an innovative, tool-free manufacturing process for producing large-format, heavy-duty rail vehicle components.
The Challenge: Conventional Manufacturing Reaches Its Limits
Today, large-format outer skin components for rail vehicles are primarily manufactured using thermoset-based fiber-reinforced composite technologies such as hand lay-up or vacuum infusion processes. However, these processes are characterized by high tooling costs, long production times, significant manual labor, and limited recyclability of the materials used.
The Solution: A Hybrid Manufacturing Chain of the Future
As part of “3D-FiberTrain,” the project consortium developed a completely novel process chain that combines three technologies:
- Large-format 3D printing: Granule-based extrusion printing enables the cost-effective production of complex geometries without expensive tools.
- Automated continuous-fiber reinforcement: A newly developed 3D tape-laying process reinforces high-stress areas in a targeted manner, following the load path.
- Machining: Automated milling ensures the highest dimensional accuracy and surface quality.
What makes it special: The entire process chain is based on thermoplastic materials and is therefore fully recyclable.
The demonstrator: Front skirt and nose of the ICE 3neo
The Velaro MultiSystem high-speed train (ICE 3neo, Class 408) from Siemens Mobility GmbH, with operating speeds of up to 320 km/h, served as the reference platform. Two challenging demonstrator components were selected to validate the developed technology: the nose and the front skirt.
The results: Economic benefits for the industry
The technology developed in the project offers significant advantages over conventional methods:
- Lower manufacturing costs – especially for small and medium production runs
- Shorter production times – due to the elimination of time-consuming tooling
- Reduced carbon footprint – through more efficient use of materials and recyclability
- Increased flexibility – rapid adaptation to design changes and component variants
The Consortium: Strong partners for innovative solutions
As the consortium leader, HVE was responsible for coordinating the overall project as well as defining the requirements, the design specification, and the structural validation of the demonstrator components. The collaboration with the project partners spanned the entire development chain:
- Fraunhofer IWU (Upper Lusatia Plastics Center, Zittau)
- Fraunhofer IMWS (Schkopau)
- Lakowa GmbH (Wilthen)
- Siemens Mobility GmbH (associated partner)
Outlook: A Technology with a Future
Tool-less manufacturing opens up entirely new possibilities for the flexible and cost-effective production of rail vehicle components—particularly for small and medium-volume production runs. HVE is convinced that this technology will bring about lasting change in the industry and make a significant contribution to the sustainable transformation of the rail vehicle industry.
The “3D-FiberTrain” project (grant number 19I23008A) was supported by the Federal Ministry for Economic Affairs and Energy and funded by the European Union. Project duration: September 2023 to June 2026.
Images: Fraunhofer IWU, HÖRMANN Vehicle Engineering GmbH
