Daimler Buses (www.daimler.com) is exploiting the benefits of 3-D printing to produce small batches of replacement parts for the Mercedes-Benz and Setra brands.

The 3-D printed parts meet the injection moulding standards stipulated by Daimler AG but avoid the costs relating to tool production, component storage and the disposal of surplus materials.

Some 780 components have been printed for customer vehicles to date (these have been made using the selective laser sintering process).

This strategy is proving particularly economical in small-series production involving batches of one to 50. The entire process — from initial idea through design, costing and production to delivery — takes only a few days.

Moreover, over 150 different replacement parts for buses are currently being assessed with regard to their feasibility as 3-D printed parts.

The multi-piece stowage compartment for banknotes, which Mercedes-Benz integrates on request in the panel on the left-hand side of the driver’s area (in place of the cup holder), is just one of many examples.

This complex component comprises the housing, various assembly clips, hinges, the lid, the handle and compartments.

The conventional production process would entail manufacturing the individual parts using various thermoforming and injection moulding tools, followed by assembly.