With SONIC, 6 Cockpits per day.
30 Cockpits per week.
130 Cockpits per month.
1560 Cockpits per year.
Producing complex, large parts like tram Cockpits presents unique challenges, especially when traditional manufacturing processes demand high investments in tooling for relatively low production volumes. This limits flexibility and can slow market entry for innovative products. The Lines SONIC addresses these constraints, offering a cost-effective solution that accelerates the production launch.
AM (with SONIC) allows full design control, enabling manufacturers to customize Cockpit features to meet specific client needs and regional regulatory standards. Indeed, in the world of railway, customer requirements vary widely across markets, regarding the geography and regulations of each country, forcing manufacturers to adjust their mobility solutions. High-Speed AM offered by SONIC becomes the perfect answer for these types of projects.
Using Lines' SONIC machine, first was produced a Cockpit prototype in a robust, accessible material, allowing our early-tester to quickly validate the concept before committing to final production. This approach allows manufacturers to test and refine their designs before moving to full-scale production. Once the design is approved, production can seamlessly shift to polycarbonate, a material compliant with rail safety standards, ensuring a smooth transition from prototype to serial production.
A key advantage of SONIC’s FGF (Fused Granulate Fabrication) technology is its use of plastic pellets, allowing an access to a huge panel of polymers. The next AM Cockpits will be produced with certified polycarbonate pellets that meet EN-45545 railway safety regulations. This allows manufacturers to continue using the same high-performance materials they rely on for traditional processes, ensuring continuity in material quality and compliance. With this asset, Lines supports historical manufacturers in maintaining their standards and certifications, streamlining the transition to additive manufacturing without majorly altering material specifications.
Cockpit first demonstrator has been manufactured in a one loop-shell with local reinforcements, strengthening the mock-up in the normal direction to the surfaces. This reinforcement varies along the Z direction. These types of “technical/structural geometries” are examples of shapes that can be done to enhance AM products.
Depending on materials, assembly operations can be achieved in post-process. On this demonstrator, headlights have been integrated at the front of the Cockpit. Enhancements will be achieved on the embedding of these parts inside the Cockpit for the next iterations. Also, the Cockpit has a frame that has been easily riveted directly after production. These kinds of operations are always optimized and industrialized when the customer passes the demonstrator step to the pre-series.
With SONIC, manufacturers can confidently enter new markets faster and more sustainably, without compromises.
