Alstom redefines the production of simulator driver desks with Caracol’s robotic LFAM technology

Caracol collaborated with Alstom to develop a full-scale simulator driver desk using its cutting-edge robotic additive manufacturing technology Heron AM.

Caracol’s LFAM platform enabled the creation of highly detailed, functional parts, very quickly, eliminating the need for machining, tooling and molds, and meeting the client’s needs in terms of validation and visualization.

Phase 1 – Project development and engineering
The technical approach to component engineering involved a detailed and collaborative process. Caracol began by thoroughly analyzing the initial CAD designs provided by Alstom to evaluate their feasibility for 3D printing with Heron AM. This step was crucial in identifying potential challenges and ensuring the designs could be effectively translated into physical components.

Based on this analysis, specific adjustments were made to the geometry. Hollow shapes were closed, ribbing and supports were added to enhance structural stability, and the layer arrangement was carefully simulated to optimize the final output.

Phase 2 – 3D Printing specifications
The part was produced in a single piece, as a hollow structure thanks to the ability to print at 45-degrees, without the need for additional supports.

Key facts

• System: Heron 300
• Extruder: High Versatility (HV)
• Nozzle size: 5 mm
• Layer Height: 1.5 mm
• Material: rPETG + 30% GF (Dahltram T-100GF)
• Printing Time: 20 hrs
• Weight: 35 kg
• Size: 2100 x 820 x 500 mm
• Lead time reduction: 5 days, vs 22 weeks
• Waste Reduction: up to 40%
• Environmental savings: >3-ton CO2 saved compared to FRP

Phase 3 – Post-Processing

• Trimming: openings that had been temporarily closed for structural integrity during printing were reopened.
• Painting: the mockup was sanded to achieve a smooth finish, suitable for painting, and finally painted to provide the aesthetic finish that the customer could expect on their train.

Conclusion
The collaboration between Alstom and Caracol has shown how it is possible to drive transformation also in highly regulated sectors such as the railways industry. By integrating innovative manufacturing methods and embracing the potential of 3D printing, Alstom is setting a new standard for speed, precision, and sustainability in producing functional prototypes and finished parts.

Want to see another LFAM innovation?
Check out the 1:5 scale Alstom train nose mockup: click here

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