Customized work for the regional train
As part of the PESA Romania rail project, Photon Laser Manufacturing GmbH is making a significant contribution to the realization of modern regional trains. The aim is to supply laser-welded side walls as welded assemblies that form the backbone of the carriage bodies. The side walls consist of a total of 14 individual elements that belong to different designs and form three carriage bodies. They are precisely manufactured at Photon, then further processed at PESA in Poland and finally put into operation in Romania.
The complexity of the components requires not only high precision in production, but also a well thought-out interplay of design, technology and process reliability - a requirement that Photon meets with a high level of expertise.
Technological advantage through experience
Photon relies on a comprehensive use of technology for implementation: robot-assisted laser welding forms the heart of production. Thanks to automated seam tracking and precisely defined parameters, this method enables particularly stable, uniform and reproducible welded joints - even with complex geometries. The process is supplemented by laser cutting, which guarantees clean, dimensionally accurate cut edges and cuts the geometries out of sheet metal panels with low scrap and pre-cutting. Depending on the material requirements, MAG and
TIG welding techniques are used. The entire production process is supported by established systems such as batch tracking and the FIFO principle, which ensures safety, efficiency and traceability.
This technological diversity is not a challenge for Photon, but part of its everyday practice - and it allows the company to master even demanding projects with confidence.
Challenges? Mastered with know-how.
Photon faced numerous challenges during the implementation of the PESA project - and consistently relied on expertise, flexibility and a solution-oriented approach.
For example, the tight production cycle places high demands on production capacity. In order to meet these demands, it was necessary to install new systems - a process that could significantly disrupt ongoing production under normal conditions. However, thanks to careful planning, forward-looking coordination with suppliers and smooth integration, Photon was able to implement the conversion during ongoing operations - without interrupting the supply chain.
The logistics of the large-format side walls also placed high demands: Transport, storage and handover had to be precisely planned and coordinated. The following solution was developed in close cooperation between PESA and Photon: a specially developed transport device that brings sensitive components to the customer safely and without damage - further proof of practical engineering skills.
International cooperation with a sure instinct
Coordination with PESA required not only technical but also communication skills. Different country-specific standards, cultural differences and time-critical coordination required intensive communication and quick reactions - areas in which Photon proved its adaptability. Regular coordination, transparent communication and close cooperation with the customer ensured that the production quality always met the specifications and the production schedule was adhered to.
Focus on templates - systematically solving challenges
Another example of Photon's solution-oriented approach was demonstrated when working with production templates. These are a tried-and-tested means of standardizing assemblies - but they quickly reach their limits when there is a large number of variants. Photon met these challenges with careful analysis, continuous maintenance and targeted employee training. This enabled inaccuracies, wear problems and design changes to be dealt with efficiently - and production quality remained stable at a high level.
Forward-looking materials management
Photon's strength was also evident in materials management. To counter supply bottlenecks, price increases and quality fluctuations, the team developed a structured material order proposal. This allows for forward planning and ensures that the required materials are available at the right time and in the right quality. This system pays off, especially when different types of materials and several suppliers are involved - through efficiency, adherence to delivery dates and cost control.
Successful all along the line
The project milestones to date show that the effort is paying off: the first technical drawings have been adapted and approved, the first side walls have been delivered and new systems have been successfully integrated. Production was optimized through the use of self-propelled, magnetic devices, the production area was expanded and the material flow was secured. The result: smooth project progress and a satisfied customer.
Sustainability with impact
However, Photon thinks beyond pure production. The technologies used contribute to the reduction of waste and the efficient use of resources. Durable components not only mean greater safety, but also a better
environmental balance over the entire service life of the regional trains. The project also promotes the regional economy, creates jobs and improves the infrastructure - both in Romania and at the Photon sites.
Future on rails
In the long term, the project will serve as a blueprint for further international collaborations. The aim is to help shape modern, reliable and sustainable mobility solutions - and to further expand its technological leadership in the field of laser-welded system assemblies. Photon is ready for the challenges of tomorrow thanks to continuous further development, partnership-based cooperation and an eye for the big picture.