Case Study: Revolution in the Production of Plastic Parts for Škoda Group Rail Vehicles

How Thermoplastic Panels Contributed to the Efficiency and Flexibility of Electric Unit and Tram Production

Škoda Transportation a.s., a leading European manufacturer of rail vehicles and other transportation technology, based in Plzeň, is renowned for its emphasis on safety, quality, and reliability. With a positive approach to innovation and the ability to respond to the diverse customer needs, the company actively contributes to the modernization and development of sustainable and user-friendly public transportation.

You can ride Škoda Transportation rail vehicles in the form of trams, trains, or metro systems in the Czech Republic, Germany, Poland, Slovakia, as well as in Latvia, and Ukraine. Additional vehicles will soon be available for railway transport in Estonia and Uzbekistan, and sleeper cars are being prepared for long journeys in Finland, Italy, and Austria.

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You can ride Škoda Transportation rail vehicles in numerous European countries, and soon in Uzbekistan.

The main goal is to increase the speed of interior paneling production without compromising on quality

To help the ŠKODA Group manage the increasing demand for electric vehicles and trams while upholding strict standards, we have devised an innovative solution for interior paneling. Customers can rely on this solution 100% for both quality and speedy delivery.

Additional customer requirements included:

Long-term production sustainability despite variable panel dimensions

Top-quality material

Increased supply chain capacity

Fast delivery

Compliance with safety standards

Anti-graffiti treatment

In Promens Zlín, we manufacture interior window panels for Škoda Regiopanter train units.

Special requirements did not derail us

Skoda Transportation prioritizes both functionality and aesthetics in its products, particularly focusing on the interior panels with variable dimensions. As the number of orders increased, the commonly used composite material proved to be unsatisfactory.

However, at Promens Zlín, we took on this challenge and found a more efficient solution that meets all necessary standards. Furthermore, by optimizing the production process, we significantly increased the customer’s production capacity.

The interior of the Škoda Regiopanter train unit features interior paneling parts manufactured at Promens Zlín.

Full steam ahead towards innovation

Po důkladném průzkumu trhu a možností jednotlivých materiálů jsme našli nového favorita: termoplast je nehořlavý, splňuje drážní normy a jeho výroba vakuovým tvářením přináší výraznou časovou i finanční úsporu.

After conducting thorough market research and exploring various material options, we discovered a new favorite: thermoplastic. It is non-flammable, meets rail standards, and its production through vacuum forming brings significant time and financial savings.

Advantages of thermoplastic for this application:

Non-flammability
Compliance with rail standards
Significant time and financial savings compared to composites
Fully recyclable

The customer had previously only used thermoplastic panels in trams. This marked their first use in train units.

In collaboration with our R&D department, we developed a prototype at our own expense for Škoda Transportation to test in practical use.

After refining the details, the prototype passed with flying colors!

We addressed the dimensional variability of the panels by developing a new modular mold with a sliding partition. This innovation was initially implemented at Promens Zlín.

As a result, the costs and the amount of waste material were reduced compared to what was initially expected from the trimming process.

To ensure that the parts are prepared for the rigorous demands of service in trains and trams, they receive a coating of an “anti-graffiti” layer after they are formed.

Window panels for Škoda train units manufactured using a modular mold. The largest panel measures 1935×1559 mm.

Please make a note of the following details about ŠKODA Group's production for trains:

There are about 30 different types of variable panels
There are 60 interior parts
The largest window panel measures 1935×1559 mm
The bonding standard is DIN 6701 A2
Example of a tailored application:
Non-flammability was a crucial consideration for the customer when choosing the new
technology and material. The material provided met the non-flammability
requirements and is also significantly lighter, reducing the overall weight of the train

Our top priority is to ensure high quality

The establishment of a dedicated certified bonding facility in our Zlín2 facility further demonstrates our commitment to the rail vehicle segment.

Highly trained workers attach seals, holders, and other mounting elements to the panels. The bonding process follows the DIN 6701 A2 standard. After a final inspection, the panels are organized into sets for each train and then shipped directly to the production line in Plzeň.

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We manufacture large-format interior paneling for Škoda Transportation’s trains and trams in Zlín, located in the heart of Europe. These parts are then sent to Plzeň for the final assembly of the vehicles. Once assembled, the vehicles are transported to Prague and other locations across the Czech Republic.

Interior parts for trams are also available

“The knowledge and expertise we have acquired from manufacturing interior components for trains is now being applied to create interior parts for new trams that will transport passengers in Prague, the capital of the Czech Republic. In addition to producing window panels, we have been entrusted with the fabrication of the interior paneling for the driver’s cabin and one exterior component – a fender, which is being manufactured using SMC (Sheet Molding Compound) technology.”

Here are the details for the production of ŠKODA 52T trams:

Number of parts:
Approximately 10 different types of parts
Number of manufactured parts:
31 interior parts and 2 exterior parts
Size of the largest window panel:
1935×1559 mm
Bonding standard:
DIN 6701 A2
Example of a customized application:
Just like with the trains, we met the requirements for cost, part weight, non-flammability, and replacing composite materials.

“I admit that we had to push ourselves a bit and weren’t afraid to veer off the beaten path. In the end, we entered the railway segment proudly and with grace.

The successful collaboration with ŠKODA Group is the result of long-term teamwork between several of our teams. Now, I have the honor to further develop this segment through my hard work.”

Ondřej Slováček

Key Account Manager

Sustainability and rail transport go hand in hand

A newly designed mold, created by experts, minimizes environmental impact and enables efficient use of the layout of the formed products. For example, reinforcements are also simultaneously formed in the window area.

The full recyclability of thermoplastic gives it an edge over composite materials.

We have produced and delivered numerous panels for Škoda Regiopanter trains
Škoda 20Ev trains are currently in use in the Olomouc region
Trams equipped with our components will commence operations in Prague starting in 2025

Welcome to the Large-Format Parts Station.
Will you hop on?

Those who do not progress will be left behind. Our facility is equipped with a 3,000-ton press and has the capability to manufacture large SMC panels up to 3m² in size.

We are looking to expand our collaboration in light of the upcoming production of new double-decker units from Škoda. Additionally, we are ready to support the accelerated production needs of other innovative rail vehicle manufacturers.

State-of-the-art production facilities for SMC technology.

Clamping force up to 3000t. This is the power offered by our largest SMC carrier.

RESEARCH AND DEVELOPMENT | PRODUCTION | PAINTING | ASSEMBLEMENT | JUST IN TIME & JUST IN SEQUENCE

We are experienced Tier 1 development suppliers.

Together, we will make your project succeed.

Ondřej Slováček

Key Account Manager

Call Us

+420 705 685 315

Mail Us

ondrej.slovacek@promenszlin.com

Modern painting plant built in 2019

Case Study: Revolution in the Production of Plastic Parts for Škoda Group Rail Vehicles

How Thermoplastic Panels Contributed to the Efficiency and Flexibility of Electric Unit and Tram Production