DB ESG has extensive experience in digital manufacturing for the UK rail sector, having started our journey with 3D printing and 3D scanning technology in 2018. Since then, rapidly expanding into the supply of digitally manufactured parts for the purposes of prototyping, tooling, and final part manufacture.
1995
DB ESG has been in operation since 1995. Originally part of EWS, it became an independent subsidiary of DB Schenker in 2007, when EWS was purchased by Deutsche Bahn. It later became a subsidiary of DB Systemtechnik, Europe’s largest rail engineering consultancy. DB ESG currently employs over 60 people in Derby, UK.
2018
A meeting between DB ESG, Angel Trains and Stratasys in Feb’ 2018 kickstarted our journey into digital manufacturing. Initial work focused on additive manufacturing – on different materials, compliance and testing before further investigation work around finishing and production was undertaken.
2019
An armrest and seat-back hand hold became the first ever 3D printed parts to enter service in the UK. The parts were fitted to a Class 165 train in the summer of 2019 and the parts remain in operation to this date.
2020
DB ESG acquire an in-house 3D printer to produce rapid prototypes for design validation and testing. This printer is regularly used to this day to support our large scale integration projects along with tackling obsolescence and supply chain issues.
2021
After delivering multiple polymer 3D printed parts, we also delivered parts that were Additively Cast and CNC Machined as well as our first parts using a powder-based 3D printing process (MJF). We would later further diversify with multiple other production methods such as welded fabrications and metal printed parts.
2022
Two 3D scanners purchased in order to carry out site surveys and re-engineer parts with identified obsolescence issues. The addition of these 3D scanners allow the whole re-engineering process to be completed in house by DB ESG.
2023
A series of complex R&D projects were undertaken covering a range of different materials and printing processes. Sustainable materials and additional materials the could comply to railway fire standards. Structurally significant components became easier to create with R&D into carbon fibre reinforced materials.
2024
Our Digital Manufacturing team grew to 6 people – with upskilling in printing and scanning across the wider business for resilience. Our in-house printing capabilities were vastly improved with a series of upgrades and modifications to our existing printer and the purchase of a second printer.
