22 meter long sidewall panel for Siemens USA

Photon Laser Manufacturing GmbH has been commissioned by Siemens USA to produce precision laser-welded stainless steel side panels with an impressive length of 22 meters. This extraordinary dimension places the highest demands on production and positions Photon as a technological pioneer in the rail vehicle industry.

Technological masterpiece in record size

The “22m Sidewalls Amtrak” project represents one of the greatest challenges in rail vehicle manufacturing: the production of stainless steel sidewalls that are 22 meters long. Bozankaya, which is responsible for the overall project, turned to Photon to overcome this technical challenge. Due to the successful delivery of laser-welded roof components for the same project, Bozankaya decided to rely on Photon again as a reliable partner – a clear proof of its outstanding expertise in laser welding and its ability to implement large-scale projects efficiently.

Precision and excellence through advanced manufacturing technology

With a 25-metre-long laser welding system, Photon is one of the few companies in Europe that can manufacture components of this size in a continuous process. The state-of-the-art technology not only guarantees exceptional quality and precision, but also significantly increases production efficiency. Advanced processes such as laser cutting and laser welding as well as comprehensive quality assurance procedures are used to meet the requirements for these large components. Particularly noteworthy is the X-ray inspection of the weld seams, which ensures both the aesthetics and structural integrity of the components.

Aesthetic challenges and flawless surface quality

The production of stainless steel side panels requires the utmost precision, especially in terms of surface quality. The material cannot be fixed magnetically and the side panels serve as a visible outer skin – they must therefore not show any scratches or defects during the entire production process. This posed a particular challenge for production.
Thanks to state-of-the-art production technologies and precise welding processes, Photon guarantees the highest aesthetic and quality standards. Close cooperation with the welding engineers (SFI) and continuous welding tests ensured that the weld seams, which would later be visible, were perfectly matched to the demanding design and functional requirements. This attention to detail ensures that the components can be seamlessly integrated into the Siemens project.

Innovative logistics solutions and close cooperation

Logistics played a central role in the success of the project. In order to transport the 22-metre-long components safely and without scratches, Photon developed tailor-made packaging solutions on wooden pallets and organized the loading of the trucks by crane. The transport to Turkey was carried out by truck and was realized in close coordination with Bozankaya. These precise logistical solutions enabled the components to be delivered safely and undamaged.
The success of the project is based on smooth cooperation between the partners Siemens, Bozankaya and the suppliers. The support from Germany made an important contribution to efficient communication between the international locations, and the rapid on-site appointments by Bozankaya Germany ensured that the project was implemented on schedule.

Milestones and successes: A clear path forward

Photon was able to achieve significant successes as part of the project: The supplier audit was successfully passed, as was the First Article Inspection (FAI), which serves as the basis for series production. Prototypes were built and delivered on schedule, while the pre-series was completed in January. The planned start of series production in March/April marks another important milestone. These successes underline not only the high quality of production, but also Photon's ability to successfully implement complex and challenging projects.

Outlook: The future of rail vehicle production

With its technological excellence and innovative manufacturing techniques, Photon Laser Manufacturing GmbH is making a significant contribution to the rail vehicle manufacturing of the future. The “22m Sidewalls Amtrak” project once again demonstrates Photon's ability not only to master the challenges of today's technologies, but also to equip the rail vehicle industry for future requirements. These innovations secure Photon a leading role in the further development of the industry.