Digital manufacturing eliminates the need for 2D drawings, reducing the time to production and ensuring the repeatability of production. What is digital manufacturing and how can it address obsolescence?ĭigital manufacturing is the design, development and production of physical parts using computer aided processes, such as CAD, Additive Manufacturing (AM, also known as 3D printing) and programmable CNC machines. For example, we recently looked at remanufacturing a custom aluminium extrusion, the supplier for which had a minimum order quantity of two tonnes! We only actually needed a single 40kg extrusion. Order quantities are also often an issue, and an operator or fleet owner may be required to order, and then store, hundreds more parts than they require, or will ever require for the remaining fleet life.

Production times can be exacerbated by external issues such as the pandemic, the war in Ukraine and Brexit. Also, legacy parts are generally expensive, have very long lead times, and are often not tailored for the specific fleet or application. Low volume parts are a real struggle for the existing supply chain and traditional manufacturing methods, leading to many operators receiving an unsatisfactory service. To keep older rail fleets operational and in peak condition, asset managers such as Angel Trains need to ensure the continued supply of parts parts that may well be obsolete or be required in very small quantities. Technology and manufacturing processes can change considerably over a 17 year period, for example 17 years ago there was no iPhone, no Twitter and no Amazon Prime with next day, never mind same day, delivery! It is notable that 65% of the UK rail fleet is over 10 years old, 25% over 25 years, with an average vehicle age of 17 years. This can create huge issues and costs for our sector. Unfortunately, the components and parts that make up these vehicles often become obsolete way before the vehicle has life expired, either because the supplier no longer exists, no longer manufactures or support these parts, or the original designs have been lost. Rail vehicles are expected to run in passenger service for over 35 years. Why is obsolescence such an issue for the rail sector?

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