MAN Relies on 3D Printing Solutions from Replique

MAN Truck & Bus, a global leader in transport solutions, relies on 3D printing using the production platform Replique to manufacture spare parts on demand, locally, and without the need to keep them physically in stock. Starting with the production of bronze manifolds for the cooling water supply of a marine engine, further projects are planned to reduce costs and further optimize service.

(Mannheim/Munich) In special machine construction, ensuring the supply of spare parts presents a particular challenge. Small quantities, an unpredictable consumption, and often very long delivery times usually make it essential to stock critical components to avoid costly downtime of equipment or machines.

In the latest application case, MAN faced the challenge of quickly procuring 10 bronze manifolds for the cooling water supply of a marine engine, which were no longer available in stock. The casting mold for this critical component was no longer available. Conventional procurement methods, which included creating models, casting, and machining, would have been both time-consuming and costly. Therefore, MAN sought an alternative solution to meet the short-term demand. This solution also had to meet the high technical requirements for this highly stressed component.

Efficient Spare Parts Management Using On-Demand 3D Printing

The collaboration with Replique enabled MAN to reproduce the 10 manifolds in original quality using additive manufacturing – all that was needed was a 3D model and a manufacturing drawing. In coordination with its material partners, Replique selected a material that is technically equivalent to the original material (m4p™ Brz10). Production was carried out using Selective Laser Melting (SLM) through a local 3D printing service office from Replique’s network of over 85 partners worldwide. From the first request from MAN to the delivery of the ready-to-install parts, only about 7 weeks passed. Tensile tests in MAN’s Central Materials Technology showed that the selected material even has technically better properties than the original. The practical application was also successful, leading MAN to place another order for 10 pieces.

The 3D-printed bronze manifolds exceed the requirements of the original part. Due to the digital availability of the production information, they can be reordered at any time in consistent quality. Since the component has already been qualified for 3D printing and a corresponding print file has been created and is digitally available, which also contains information about the material and technology used, manifolds can be reordered at any time in consistent quality in the future. For MAN, there are no fixed costs for molds and models, as well as storage costs. This results in attractive total costs per piece for small quantities.

Another Project Already in Planning

“The collaboration with Replique was exceptionally good from the first contact to the receipt of the finished components! This allowed us to quickly assist our spare parts customers, and together with Replique, we are already working on the implementation of another 3D printing project,” says Thomas Hauck, Spare Parts Logistics MAN. “The use of additive manufacturing allows us to overcome traditional production challenges. We are pleased to ensure a reliable, efficient supply of spare parts in the transport and marine sector together with MAN,” says Dr. Max Siebert, CEO and Co-Founder of Replique.