PROFESSIONAL BLOG
AUGUST 16, 2024 • 6 MIN READING
This is what one of the world's largest train manufacturers wants Plexx to make for them
One of the world's largest train manufacturers is working to streamline production – and Plexx came through with the right combination of quality, price and technical solution.
Jon Jørundland
COO, Plexx
One of the world's largest train manufacturers is working to streamline production. This means that many of the parts can be used across the different train types. Plexx came through the eye of the needle and met the requirements for quality, price and technical solution.
Plexx has supplied many parts through the manufacturer Bombardier, for the production of the Flytoget. We have therefore become an approved supplier to one of the world's largest train manufacturers.
The train manufacturer has the widest range in the industry
From high-speed trains, metros, monorails and trams, to turnkey systems, infrastructure, signalling systems and digital mobility, the company offers the widest range in the industry.
They are present in 63 countries with over 80,000 people from 175 nationalities – and set the standard for modern, sustainable public transport.
An exciting pilot project with one of the world's largest train manufacturers
As part of its efforts to streamline train production from a sustainable perspective, the company is now testing a model that involves using the same parts across different train models. The parts Plexx will produce will therefore be used on all of their train models.
"The production method we will use to produce the shafts is Twin Sheet. Twin Sheet combines vacuum forming and pressure forming by forming and welding two plates together in the same process."
That is why we chose this production method
Plexx will supply parts for the ventilation system. These are shafts that come down over the windows, and one of the requirements is that they must be fire resistant.
The Twin Sheet method creates a product that is hollow and dense, without the use of glue or other joining techniques. The Twin Sheet process produces three-dimensional details with surfaces according to specification. Typical properties of a Twin Sheet product are strength and stiffness combined with low weight. Twin Sheet products can also be filled with foam inside.
More uses for Twin Sheet
Transport and logistics
Pallets, containers and transport units with built-in reinforcements and low dead weight.
Medical equipment
Containers, enclosures and load-bearing structures with clean surfaces and stable geometry.
Cabinets and enclosures
Various types of cabinets where strength, insulation and low weight are all important at the same time.
Leisure equipment
Robust, lightweight parts that withstand use in demanding environments over time.
Ventilation products
Shafts, ducts and covers with tight joints and fire-resistant properties.
Planes, cars and trains
Structural and functional parts where every gram counts and the requirements are strict.
Frequently asked questions
The train manufacturer has strict requirements for both quality, price and technical solution — and suppliers must go through a thorough qualification process before they are approved. Plexx was chosen because we could document production capacity, quality system and technical expertise at the level required for the train industry. In addition, we have previously supplied many parts through the manufacturer Bombardier to Flytoget, which gave us a strong reference into the process.
The company is testing a model where the same components are used across multiple train models — from high-speed trains and metros to trams and monorails. This reduces the number of unique parts, simplifies spare parts logistics and enables more sustainable production. The parts Plexx will supply will therefore potentially be used across all of their train models, not just one platform.
We will supply parts for the ventilation system — specifically shafts that are mounted above the windows in the passenger cabin. These distribute air into the compartment and must also meet the rail industry's strict requirements for fire resistance, smoke generation and toxicity (often referred to as EN 45545 or equivalent standards).
Twin Sheet creates a product that is hollow and tight — without glue, welding or other joining techniques. It provides tight air channels in one continuous part, with high rigidity and low weight. The combination of a hollow core, double walls and the possibility of internal foam filling makes the method particularly well suited for ventilation parts where strength, weight, fire resistance and precise geometric details are important at the same time.
Fire resistance is mainly solved through material selection. We use thermoplastics that are certified for the fire requirements of the train industry — typically flame retardant qualities with documentation of flammability, heat release and smoke development. Geometry and wall thickness also play a role, and we can combine different materials in the Twin Sheet construction where different properties are needed on the inside and outside.
Two thermoplastic sheets are heated simultaneously to the correct forming temperature. They are placed in a double-sided tool, where vacuum draws each sheet towards its own half of the mold. At the same time, the edges are pressed together under pressure, so that the sheets fuse together and form one dense, hollow part. The result can be formed with three-dimensional details on both sides in the same operation, and the surface can be specified as required.
Becoming an approved supplier to one of the world's largest train manufacturers is a strong seal of quality for the entire business. It opens up new projects both within and outside the train industry, and it commits us to further develop our expertise in advanced production methods such as Twin Sheet — so that we can continue to offer solutions that are at the forefront of technology, quality and sustainability.
Do you have a project that requires Twin Sheet?
If you have any questions about the project or would like information about Twin Sheet or other plastic production methods – please contact us.