DB ESG’s Pioneering Digital Engineering Service
DB ESG is at the forefront of rail innovation, using its cutting-edge Digital Engineering (DE) Service to revolutionise component production. Using advanced computer-aided processes such as 3D scanning and additive manufacturing (3D printing), DB ESG delivers rapid, cost-effective solutions to the rail industry.
In 2019, DB ESG became the first in the UK to place 3D-printed parts into commercial service on passenger trains. Since then, it has expanded rapidly, supplying DE components and services to OEMs, TOCs, and ROSCOs. To date, DB ESG has successfully completed over 100 projects for more than 20 customers, addressing component supply challenges and solving engineering problems efficiently.
The company’s project portfolio is diverse, ranging from small, flexible clips designed to replace brittle originals that failed during overhaul—delivered within six working days to minimise service disruption—to large, impact-resistant underframe protection panels that safeguard vital systems and circuitry.
DB ESG’s DE service operates across three key workstreams:
- Obsolescence solutions
- Engineering problem-solving
- 3D scanning
Initially focused on mitigating component obsolescence, DB ESG now produces parts from a wide range of materials, including metals, without minimum order constraints. This enables rapid part production, often within days, helping keep fleets operational and maintenance schedules on track. Unlike traditional manufacturing, DE incurs no setup or tooling costs, offering a flexible, on-demand service. If technical drawings exist, DB ESG works from them; otherwise, 3D scanning is used for rapid digitalisation and re-engineering. This approach enhances reliability by eliminating common failure modes and improving part quality.
Beyond manufacturing, DB ESG uses DE to streamline engineering tasks. For example, it has developed custom jigs for installation and maintenance projects, significantly reducing labor time and complexity. In depots, 3D scanning has replaced lengthy ultrasonic testing, cutting inspection times from hours to minutes while providing richer data insights.
DB ESG has also deployed 3D scanning for critical safety applications, such as assessing fuel tanks for deformation, weld failures, and structural issues. Many customers are now incorporating these digital checks into routine maintenance schedules, enhancing both vehicle safety and operational efficiency.
For more information, contact 3denquiries@dbesg.com or visit www.deutschebahn.com/dbesg.