3D Metal Printing for Rigi Railways: Spare Parts Solution After 40 Years

When original spare parts are no longer available after 40 years of operation, downtime is a real threat. When a seized bearing destroyed the connecting rod and piston in the air compressor of a RIGI BAHNEN AG shuttle train, Gilli Motors collaborated with Feramic to recreate them.

3D Scanning, Material Change & CNC Finishing from a Single Source

To make the unit operational again, we at Feramic took over the complete reproduction of the connecting rods:

• Digitisation & Drawing: Using an intact component fragment, we captured the geometry using high-precision 3D scanning and transferred the tolerances into a production-ready technical drawing.
• Material Selection (Aluminium CP1): Instead of the original cast material, we chose Aluminium CP1. This material offers superior mechanical properties and is ideal for the stresses within the compressor.
• Additive Manufacturing: Using layer-by-layer 3D metal printing, four raw connecting rod components were created with very high density and material quality.
• Mechanical Post-processing: We performed the precision fits and mechanical finishing on our CNC machines, allowing us to deliver ready-to-install components.

Reliable Compressed Air for Thousands of Passengers

The repaired compressor unit was successfully put into operation and has been running completely fault-free ever since. Especially during the busy summer months, the shuttle trains ensure that thousands of visitors can reliably enjoy their trip to Mount Rigi.

Value Added in Numbers

• 4 Connecting Rods Recreated: All required components replaced with a perfect fit.
• 100% Ready to Install: Delivered ready for immediate assembly thanks to combined CNC post-processing.
• OEM Independence: Successful overhaul despite the manufacturer having discontinued spare part supplies.

"When spare parts can no longer be sourced for 40-year-old units, pragmatic and technologically advanced solutions are required. The connecting rods recreated by Feramic fit perfectly."
— Martin Horath, Workshop Manager Goldau, RIGI BAHNEN AG