In 2015, Daimler Buses initiated a decisive transition from using additive manufacturing (AM) mainly for prototype production to series production. This shift has not only changed how parts are manufactured, but also created a new digital business model for the auto giant. To find out more, we spoke to Ralf Anderhofstadt, Head of the Additive Manufacturing Competence Center at Daimler Truck | Daimler Buses, who explained the company’s journey to adopting AM, the factors that led to the creation of the consulting division AMS – Additive Manufacturing Solutions, and his future plans for 3D printing in the automotive industry.

Transition from prototyping to series production

Daimler Truck & Buses began its foray into additive manufacturing by testing and validating the potential of 3D printing for the production of series parts. The transition from prototyping to series production required strict technical and quality approval processes, special material developments and numerous certifications.

“In 2015, we started testing and validating the leap from AM for prototype production to series production at Daimler Buses. In addition to technical and qualitative approval processes, special material developments and numerous certifications, we qualified and implemented a large number of spare parts and series parts using AM in the years that followed,” explains Anderhofstadt.

Ralf Anderhofstadt, Head of the Center of Competence Additive Manufacturing at Daimler Truck | Daimler Buses.

The extensive groundwork during this time paid off, as Daimler Buses realized that AM was more than just another production technology. It offered a new digital business model that went beyond manufacturing and opened up opportunities for cross-industry collaboration. This realization led to the establishment of AMS – Additive Manufacturing Solutions, a consulting unit established to explore the exciting field of industrial 3D printing in collaboration with other companies from various industries.

The birth of AMS – Additive Manufacturing Solutions for Daimler Truck

As AM technology gained traction at Daimler Truck & Buses, numerous companies from different industries approached the truck and bus manufacturer with questions about getting started with 3D printing on an industrial level. Daimler Buses recognized the potential to share its expertise and founded the consulting unit to help other companies use AM technology.

Anderhofstadt highlighted AMS’s comprehensive range of services: “Within the framework of AMS – Additive Manufacturing Solutions, we cover the entire digital value chain in line with our internal approach at Daimler Truck. This includes various workshop and consulting packages from quick start to part screening, digitization and brand protection to well-founded quality management packages and certified approval processes.”

AMS – Additive Manufacturing Solutions positions itself as a full-service provider. In addition to the areas already highlighted by Anderhofstadt, an important offering is an all-encompassing Software-as-a-Service (SaaS) package that helps customers manage the complexity of adopting 3D printing technology.

In addition, AMS has expanded its service offering to include data preparation and digital warehousing. With this service portfolio, customers benefit from the flexibility of AM, especially in situations where parts are difficult to obtain or suppliers are unavailable.

Using AM despite supply chain disruptions

The COVID-19 pandemic had a profound impact on global supply chains, causing delays and bottlenecks in various industries. For Daimler Trucks & Buses, AM proved to be a valuable tool for overcoming these challenges. “During the pandemic and up to today, there are still numerous missing parts and supply chain delays in various industries. Since then, industrial 3D printing has been able to play to its strengths in a more profound way,” says Anderhofstadt. In addition to the partnership with certified AM service providers, this led to the construction of a mobile “mini factory” for the decentralized production of 3D-printed spare parts.

The mobile printing center in container form contains all relevant stations for spare parts production using 3D printers in an area of ​​just 36 m2.

Daimler Truck & Buses has already 3D printed over 100,000 bus spare parts and digitized over 2,500 more. With its Digital Parts Warehouse, the company enables the management and retrieval of 3D models, ensuring that key parts can be produced on demand. This significantly reduces storage costs and transport distances. Thanks to this capability, the company was able to mitigate some of the supply chain disruptions by quickly producing parts on demand, thereby reducing dependence on traditional supply chains.

Compliance with industry standards and regulations

One of the biggest challenges in introducing AM for series production is ensuring that the parts meet the automotive industry’s strict quality and reproducibility standards. “Series production through AM is only possible if these aspects are 100% assured,” emphasized Anderhofstadt. Daimler Buses has invested a lot of time and energy in developing sound approval processes and certifications to ensure that the 3D printed parts meet all requirements.

To this end, AMS offers comprehensive additive preparation services, including data generation, which involves scanning and reconstructing to create 3D models, and product protection through exclusive branding and texturing options. These services ensure that AM components not only meet quality standards, but also comply with brand-specific requirements.

The future of additive manufacturing at Daimler Truck

Daimler Trucks & Buses plans to expand the use of AM to other materials and components in series applications. “We are convinced that the number of materials and components for series applications at Daimler Truck & Buses will continue to increase significantly in the coming years,” says Anderhofstadt. This expansion will be driven by specific material developments and further approvals of various 3D printing processes for series applications.

In order to be able to supply bus customers with spare parts more quickly, Daimler Buses has created a mobile printing center with its service brand Omniplus for the decentralized production of 3D-printed spare parts.

Another crucial aspect of the future of AM lies in its integration with digitalization efforts such as digital twins, virtual warehouses and digital rights management. Daimler Truck’s Digital Parts Warehouse, for example, offers sustainable and future-oriented management and security of 3D models and enables companies to optimize logistics and procurement. This digital transformation not only supports faster and more flexible responses to demand, but also contributes significantly to sustainability efforts by reducing storage costs and transport routes.

Daimler Trucks & Buses’ journey from using additive manufacturing for prototypes to launching its own AMS service underscores the transformative potential of additive manufacturing in the automotive industry. By using AM, Daimler Truck has not only improved its manufacturing capabilities but also opened up new digital business models and opportunities for cross-industry collaboration. As the technology continues to evolve, Daimler Truck is well positioned to stay at the forefront of the AM revolution and drive innovation and sustainability in the automotive sector.