Innovation for More Comfort and Sustainability in London’s Underground

In November 2018, Transport for London awarded Siemens Mobility the contract to deliver 94 nine-car trains, which are scheduled to be in operation by 2025. Alongside passenger comfort, sustainability is a central criterion of this massive investment project. The state-of-the-art Inspiro family deep-tube trains are composed of 95 percent recyclable materials, ensuring their reliable service for many decades to come thanks to their future-proof design.

Sustainability and Efficiency through Modern Manufacturing Methods

Photon is involved in manufacturing the front masks of the new trains from metallic raw materials. These masks, compared to conventional plastic ones, are significantly more sustainable but also more challenging to produce: The challenge lies in the initial design and construction of a component that, due to its size, geometry, and depth, cannot be manufactured in one piece from this material. In addition to the extreme requirements for dimensional accuracy and flatness, the particular challenge lies in segmenting the component in such a way that the individual parts can be manufactured using Photon’s state-of-the-art deep-drawing facilities and subsequently welded together to form the installable front mask.

Outstanding technology in action: Photon’s deep-drawing presses

Thanks to its advanced deep-drawing presses, Photon was able to fully meet the specific requirements for component. Once again, Photon’s extensive experience and expertise in deep-drawing large components and connecting them through conventional welding were crucial. The result is a front mask for the new Siemens trains that is not only 100 percent recyclable but also significantly more durable and easier to repair than conventional plastic front masks. This project for the London Underground serves as an excellent example of how Photon’s deep-drawing presses can continue to contribute to increased efficiency and sustainability in the future.