The new flagship of the DB fleet will be in use for decades – reaching top speeds of up to 250 km / h.

For the outer shell, this means meeting the highest standards in terms of stability and workmanship. But it also needs to be lightweight. Because every superfluous gram of weight travels over millions of kilometres, worsens the energy balance and thus causes higher costs in the long run. Quite a challenge for the Siemens/Bombardier carriage builders.

The Photon solution: steel and laser. Laser-welded carriage components made of sheet steel offer maximum stability even with low material thicknesses – without space-wasting internal reinforcements, which are necessary when using aluminium, for example.

Photon’s XXL laser welding portals allow even the thinnest steel sheets to be welded with the highest quality, precision and strength – efficiently, quickly and with no visible welds on the outer skin. This saves time, money and materials in the production process, creates space in the interior of the train and reduces the environmental impact of the ICE 4.

A solution that has convinced Siemens/Bombardier. Over the next few years, Photon will produce sidewalls, roof assemblies and underframe components for approximately 1,600 ICE 4 carriages. And in many other trains, too, there is more than just one piece of Photon. For the competition, this means:

“Stand back please!”

Since 1990, the Rocky Mountaineer has crossed the vast, majestic landscapes of western Canada and the United States. What makes these trains so special are the big, domed windows, which offer breath-taking, panoramic views of the magnificent landscapes.

The production of the carriages is anything but easy: greatest possible stability and safety are as important as a unique aesthetic befitting the exclusive clientele.

Particular challenges are the sheer size of the carriage bodies (about 25 m long) and the heavy steel construction with extreme material combinations (thin sheet metal with high profile thickness). Clearly a job for the XXL laser-welding pioneers from Photon.

From the beginning, Photon specialists were involved in the design of the components. The required technology and the semi-automated production process for the small series were also designed and implemented by Photon.

When producing the sidewalls, end walls and roofs for the carriage bodies produced by Stadler GmbH Pankow, Photon pushes at the limits of laser welding technology – in terms of component geometry as well as tolerances and material combinations.
Where others have failed, the Photon engineers and welders achieve excellent results due to their experience and absolute passion for the potential of laser.

Which goes to prove that with Photon, going West is anything but arduous.

The 60 brand-new ET 490 trains of Hamburg’s S-Bahn are not only more efficient and more comfortable than previous models, they also look better from the outside. This is in no small part thanks to the rail-vehicle experts at Photon.

By 2019, Photon will have manufactured solebars and double T-beams for a total of 180 carriages. In addition to the technical specifications, the aesthetic requirements are high, because the solebars are visible. This requires precision laser welding in 3D, with twelve-metre-long components, of course with welding seams that can’t be seen on the outside.

The finished trains are real gems and a testimony of Photon’s expertise. But the manufacturer Bombardier Transportation also benefited from Photon’s comprehensive know-how in the field of rail-vehicle construction in other ways – for example, in the development of the overall manufacturing concept and in the design and optimisation of components.

And perhaps most importantly, the new vehicles are a hit with Hamburg residents as well as visitors to the Hanseatic city.

The diesel-electric locomotive SC-44 Charger has been produced by Siemens Sacramento since 2015. The major project involves 600 locomotives for various North American rail companies such as Amtrak, IDOT, Multistate, SEPTA and CALTRANS.

The deep-drawing experts at Photon were commissioned with manufacturing the deep-drawn roofs, side panels, front masks and coupling covers. For good reason – because producing front masks which differ from operator to operator is extremely demanding.

For example, tools of up to 20 tons in weight have to be produced for the forming of very large, very deep components made of extremely strong materials. Compensating for the spring-back effect of the components in the tools is also very demanding and requires the expertise of the experienced Photon team.

Advance forming simulations, design improvements and a step-by-step optimised production process make even the most difficult aspects possible. A true masterpiece, which the Photon tool-making and deep-drawing specialists are rightly proud of.

Fun fact: In the US, trains are no longer ambushed, but they are still often shot at – which explains the extreme robustness of the locomotives.

For the prototypes of the new truck series, Photon produced several demanding assemblies such as front centre panels, cabin corners and cladding-frame parts in four different sizes. For this purpose, 28 tool sets had to be designed and manufactured in a short space of time, some of them weighing up to 15 tons.

Not only the production of the outer skin parts proved to be a challenge; bonding them with the inner structural parts by gluing and seaming proved to be difficult, too. To do so, Photon designed and manufactured eight seaming tools and other equipment for laser cutting and constructing assemblies.

Once again, the result spoke for itself: it is not for nothing that Photon continues to be a reliable partner for the automotive and commercial-vehicle industry when it comes to the fast, flexible and accurate production of components and assemblies for prototypes and small series.

Form and function are perfect combined in the BMW X6. That’s why the Italian supplier CO.ST.AT. wanted to leave nothing to chance in the production of the trunk lid and turned to Photon. The task: joining two deep-drawn components made of electrolytically galvanized sheet steel by means of laser-beam soldering.

Worldwide, Photon has the longest experience in designing and implementing laser-beam soldering processes on trunk lids (since 1996) and is therefore the obvious choice for carrying out highly complex projects in this area in the shortest possible time.

In addition to high-quality implementation, planning is crucial. It is important to strike a perfect balance between the implementation of the component design and the requirements and limitations of the production process.

During the planning stage for the trunk lid of the BMW X6, Photon worked together with the customer and the end customer using 3D CAD data. Based on the resulting designs, Photon constructed a tensioning device for the laser-soldering process. Furthermore, as a partner of the deep-drawing tool manufacturer, Photon set up the supply chain for the pre-production series before it was handed over to the end customer BMW.

Thanks to Photon’s extensive experience, the process was completed in a very short space of time – with fewer unused components than originally estimated. The quality of the assemblies immediately convinced both CO.ST.AT. and BMW.

The eyes of the world were on the exclusive car brand Bentley when it announced the production of its first SUV. All the more important that everything went smoothly in the test phase. The welding of the body seams for the pre-production models was a particularly sensitive issue. Warping through heat can lead to rippling (bumps on the roof). Other process errors (pores, holes, splashes) can also be very difficult to rework in the outer skin area of ​​the aluminium body – which can lead to the roof needing to be renovated or even to the loss of the entire body.

That’s why the manufacturer left nothing to chance and entrusted Photon’s highly skilled laser-welding experts with the difficult task. A major vote of confidence, which incited Photon to peak performance.

By means of a tensioning device designed by Photon, the roof segments and sub-segments of the aluminium bodies, delivered under the highest secrecy, were positioned with micrometre precision. In the Photon laser-beam welding portals, the roof seams of all bodies could then be joined, as planned, with minimal warping.

In the subsequent test phase, the pre-production models were a great success, series production started, and in 2016, the first vehicles were delivered and celebrated by car enthusiasts worldwide.

How do you make a good engine even better? This was the question faced by the engineers of Rolls-Royce Germany in the development phase of the turbofan engine BR725, which is a further development of the BR710.

A possible area of optimisation was the exhaust cone, usually made of nickel-based steel. The alternative: titanium – an expensive but very popular material in aviation due to the fact that it is strong, corrosion-resistant and lightweight.

For the manufacturing, RR turned to Photon – and received an attractive overall package: from comprehensive planning and design to cutting, rolling and bending of individual parts, coordination of the necessary forming processes, right through to 3D laser-beam welding in Photon’s state-of-the-art laser welding portals.

The Photon specialists did a great job: they were able to reduce the weight by over 30%, while meeting the highest standards in terms of quality, safety and resilience.

In the end, titanium wasn’t used in the exhaust cone, but in the fan. And the BR725, which among other things powers the Gulfstream G650, the world’s fastest and longest-range business jet, is actually quieter, more economical and cleaner than its predecessors.

Titanium and laser – an unbeatable combination from Photon.

The Rolls-Royce Trent XWB is one of the world’s most advanced jet engines. An important optimisation compared to other models are the one-metre-high Outlet Guide Vanes (OGVs) made of titanium – a material that offers a higher resistance to abrasion compared to the more commonly used fibre composites.

However, titanium is heavier than a fibre composite. The solution: to design a hollow construction offering the same safety and stability as a solid construction.

A particular challenge is the low-distortion and rework-free welding of the end cover on the hollow body, because the component is 1 m long but the titanium used only 1 mm thick.

To overcome this problem, RR turned to Photon during the development stage. Using very high welding speeds, even for the rounded corners, the Photon laser experts were able to apply the covers with low tolerances.

During the production of the OGVs, Photon was responsible for the engineering and the 3D laser-beam cutting and welding of the components. And it turned out to be an important contribution: the innovation was adopted in the serial production of the engine.
The project XWB shows: Photon goes through thick and thin for its customers – literally.

Everybody knows the “good old“ ticket stampers: Sometimes you can hardly read the stamp, malfunctions are common and maintenance is costly because daisy wheels and colour ribbons need to be cleaned and replaced again and again.

Since Photon started producing the thermal ticket validator together with patent owner Technical Service W & P in 2017, numerous railway companies throughout Europe have been equipped.

Thermal printing does not work with mechanical pressure, but with heat generation. Also, there is no colour carrier – the image is created by a heat-sensitive coating on the paper. As a result, maintenance and material costs are low. In addition, this solution is characterized by high printing speeds and sharp images. That is why thermal printing is perfectly suited for the printing of tickets.
Photon has technologically optimised and standardised the thermal ticket validator based on previous models, resulting in an extremely low installation and assembly effort. The layout design of the thermal dispenser can be adjusted individually, according to customer specifications.

The thermal validator is entirely manufactured by Photon. Production includes laser cutting, bending and welding of the sheet metal housing, powder coating and final assembly of the electronic functional assemblies, including the logo or pictogram. Protection type testing according to DIN 40050 (IP43 for necessary openings such as card insertion) is also done by Photon.

The thermal validator can be used either as a mobile device or as a stationary system. For stationary operation in railway stations, a support base, also developed and manufactured by Photon, is available.

An extension of the thermal ticket validator as a digital cash processing and passenger handling system with 3D barcode reader, Bluetooth interface, WLAN, NFC and IP is in preparation.

Combining clean, i.e. largely germ-free and virus-free air with intelligent lighting concepts – that’s what Cleantec Lighting GmbH from Leisnig is all about. Photon is responsible for advancing and manufacturing their flagship product, the Cleantec Air sterilization and lighting system, and adapting it for a broad range of applications.

Photon has not only made the system fit for optimal use in medical practices. Customers can also draw on our well-founded production and approval know-how in the railway sector, namely trains and other public transport. Thus, as of 2020, a modified version will be available in trains and help reduce the risk of infection for passengers.

In addition to the laser cutting, folding and welding of the housing, the powder coating and the final assembly of the electronics (including functional tests) are also done at the Photon site in Meissen.

The air sterilization and lighting system is predestined for a wide range of applications, e.g. offices, training and meeting rooms, businesses, pharmacies and clinics.

With many years of experience and in-depth manufacturing expertise, Photon is able to scale and shape the product to fit any area of application – from the mounting on ceilings or into tables and walls, to the installation under passengers’ seats in public transport.

With the development of the SEW95-LWL glass-fibre connection box, Photon offers the possibility of replacing the hitherto existing copper-fibre terminals used for distribution and connection technology (safety and signalling applications) in the track area.

These are fundamental to the construction of digital interlockings within the European rail network.

The Photon connection box SEW95-LWL is suitable for the space-saving and secure integration of sensors and signals in a fibre-optic data transmission ring. The innovative model is based on the proven type SEW95-2 for signalling applications.

The SEW95-LWL connection box contains fibre-optic splice cassettes for up to 48 fibres as well as up to four pre-mounted outdoor duplex couplings, including glass fibres. For the connection of sensor and distribution technology, pre-assembled connecting cables with outdoor plugs in various lengths are available.

These allow an optimised mounting process and a quick maintenance by replacing the easily detachable plug-in-connector. The first sample assembly was realised in November 2018. The testing and approval process at the German Railway (Deutsche Bahn) has thus started.

Trains also need electricity on sidings or in freight depots – e.g. for the central computer. That’s why special supply points are provided at these locations. But who consumes how much electricity and when?

The Deutsche Bahn wants to know exactly – to allow for accurate assignment and billing. The question: How do you reach a functional solution fast and cost-efficiently?

Enter Photon.

Photon combines many years of rail communications experience with in-depth expertise in the manufacturing of electric vehicle charging stations and also has the required certifications – a rare combination.

That’s why Photon was able to quickly come up with its own innovative solution: an intelligent power-supply column, which for the first time enables centralised and accurate monitoring through integration in the GSM-R network of the Deutsche Bahn. Billing works via the OCCP system, which is also used in charging stations for e-vehicles.

The Photon Elektrant Smart ID is developed and manufactured from A to Z by Photon (excluding foreign parts) – including the complex inner life. Over the next few years, Photon will deliver many of the bright yellow pillars – making an important contribution to digitising rail infrastructure in Germany.

Call barriers are barriers at seldom-used railroad crossings in Germany, which are kept closed permanently or during certain periods and are opened at the request of road users if required. Communication with the control centre takes place via a communication pillar.

As part of the modernisation of the railway infrastructure, the existing wired communication pillars are to be replaced by new wireless pillars.

For this purpose, Photon developed a communication pillar for the Deutsche Bahn AG, which enables wireless communication and integrated monitoring via integration in the GSM-R network. Power is supplied via solar panels on the column. In addition to improved functionality, the new pillars are also much more economical than the old ones, costing two-thirds less.

With this solution, which is unique in Germany to date, Photon is responsible for the manufacturing as well as the development of the plastic housing, as well as for the final assembly of the functional modules, including a functional test. 100 to 150 level crossings are to be equipped with two GSM-R communication pillars respectively.

Thanks to many years of experience in the rail sector, Photon was able to successfully master the considerable challenges with regard to safety, compatibility and compliance in close cooperation with DB AG.

An innovative Photon product, which should also be interesting for other markets.

As part of Germany’s Combined Heat and Power Act, Babcock Borsig developed the MGT100 micro gas turbine.

The aim was to enable considerably more efficient and environmentally friendly decentralised combined power and heat generation (e.g. in trade businesses) than with conventional solutions such as diesel generators.

A heat exchanger (recuperator) was designed, which consists of a number of extremely thin sheet-metal partitions to heat up sucked cold air using the warm exhaust gas flow.

But how thin is possible? The answer was provided by Photon. Instead of conventional 1.0-mm-thick sheets, Photon succeeded in producing a heat exchanger made of 0.1-mm-thin, corrosion-resistant stainless steel foil. An innovation that was made possible only by the many years of experience and technical possibilities of the laser-welding experts from Berlin.

Photon was responsible for engineering (consulting, design, process, components), 2D laser-beam cutting, forming, and 3D laser cutting and welding of the ultra-thin foils.

The result? The procurement volume of the material and the weight were reduced by up to 90%, while efficiency increased by 7%.

A clear case for Photon. In-depth laser know-how and laser-welding capacities up to XXL make it possible to join even large components to the highest quality standards. Photon is able to weld alternately large or small, straight or angular, with or without a recess – fast, flexibly and precisely.

In order to achieve the desired flexibility in the production of the unique components for a yacht construction project, however, the guide system of the laser welding head had to be completely redeveloped. Only then could the desired variability be implemented with very short lead times.

In the end, Photon was able to deliver the laser-welded components (decks, walls and cross frames) from shipbuilding steels in the required quality and on time.