At Promens Zlín, we apply our expertise in manufacturing plastic components for rail vehicles to the production of interior window panels for the Škoda 49T trams operating in Bergamo, Italy. Projects of this type require the perfect combination of high-quality materials, precision manufacturing, compliance with strict railway safety standards, assembly capabilities, and reliable logistics.
The Challenge: Interior Window Panels for a Modern Tram
Interior components for rail vehicles must meet demanding requirements for safety, durability, and visual appearance. At the same time, they are manufactured in series production, where repeatability, process stability, and reliable delivery performance are essential.
For projects like this, Škoda Transportation places particular emphasis on:
- Compliance with railway standards
- Fire-resistant materials
- High-quality visible surfaces
- Dimensional accuracy
- Low component weight
- Efficient manufacturing processes
- Reliable deliveries to the assembly line
- Pre-assembly of components before shipment
The Solution: Thermoplastic Window Panels and Optimized Manufacturing Processes
Our solution builds on extensive know-how gained from manufacturing interior components for train units and other tram projects. Instead of traditional composite materials, we use thermoplastics manufactured using vacuum forming technology, providing a more efficient and sustainable solution for rail interior applications.
Thermoplastics offer several advantages for rail vehicle interiors:
- Compliance with railway industry requirements
- More efficient manufacturing
- Lower production complexity compared to composite materials
- Full recyclability
- Greater flexibility when producing components in different dimensions
Modular Tooling for Better Material Utilization
Another key part of the solution is optimizing tooling and material utilization. For this family of window panels, Promens Zlín developed a modular forming tool with a movable partition, allowing efficient production of different panel sizes while maximizing material efficiency.
The modular tooling solution helps to:
- Reduce material waste
- Minimize unnecessary trimming
- Improve utilization of the formed sheet
- Increase production efficiency
- Support more sustainable manufacturing of plastic components
Assembly and Preparation for Final Installation
As with many other rail vehicle projects, our scope of supply extends beyond thermoforming. It also includes a range of downstream operations such as surface finishing, bonding of seals and mounting elements, quality inspection, packaging, and preparation for shipment.
Bonding operations for rail vehicle components are carried out at our certified production facility in Zlín 2 in accordance with EN 17460:2022 – A2, ensuring consistent quality and compliance with railway industry requirements.
The Result: Rail Industry Expertise Applied to an International Project
The Škoda 49T project for Bergamo demonstrates how expertise in developing and manufacturing plastic components for rail vehicles can be successfully transferred across different vehicle platforms and international markets. By combining advanced vacuum forming technology, certified downstream processes, and reliable logistics, Promens Zlín delivers complete manufacturing solutions that meet the demanding requirements of the rail industry.
