St. Louis’s Bi-State Development Agency has realized more than $48,000 is cost savings this past year by printing 3D replacements for discontinued and custom-made parts for older Metro Transit MetroLink LRVs and MetroBus and Call-A-Ride vehicles, vs. purchasing them.
“From 3D printing critical parts to supporting running repairs and component overhauls for the light rail fleet, the mechanics working in the maintenance department at Metro Transit’s Central Facility play a vital role in day-to-day operations,” the agency said. “Beyond keeping hundreds of MetroLink, MetroBus and Call-A-Ride vehicles running efficiently year-round within a 500 square-mile service area in Missouri and Illinois, these valuable team members are providing creative solutions that solve complex problems and deliver bottom-line savings for Metro Transit.”
Approximately 60 mechanics are employed at the Central Facility, Metro Transit’s main repair shop. The shop includes painting facilities and transmission overhaul and also houses the Real Time Camera Center where the public safety team monitors activity in real time across platforms, trains and buses. Among the newest equipment is 3D printers for manufacturing parts. Purchased in 2024 for $51,200, the printers “have proven to be a real game changer,” as they are being used to improve upon existing parts and to reproduce parts that have been discontinued by the manufacturer or are not readily available due to supply chain issues,” Metro Transit noted. Many of these parts are custom-made items that would otherwise be unavailable or cost-prohibitive to source. Items printed specifically for the light rail system have included cup holders, traction motor covers and gaskets, mirror arm to head blocks, air gauge covers, cable spacers, housing seals and more. All have been produced at a fraction of the manufacturer’s price and, in many cases, improve on the original part being replaced.”
For example, the Central Facility team was able to print the mirror arm to head blocks for approximately $1.85 each, an alternative to paying $60 for each replacement part through the vendor. In terms of improvements, a redesigned traction motor cover adds a lip to prevent water intrusion into wire connections, improving LRV long-term reliability. The team also created a 3D printed replica of the LRV dashboard for operators to sit at and provide feedback on the ergonomics of the new Siemens LRV 5 dashboard design. To date, the agency has printed more than 7,500 parts in-house.
“In addition to delivering time and cost savings, the mechanics can control quality and provide components that are quickly becoming obsolete but are still necessary for maintenance on Metro Transit’s fleet,” the agency noted. “The ability to contribute in such a meaningful way to the organization appeals to the team members, who see their position not just as a job, but rather as a career with upward mobility. A mentoring program in partnership with ATU (Amalgamated Transit Union) will help to ensure the maintenance team continues to excel as new mechanics join the ranks. Metro Transit has open positions available now and is hiring mechanics who are eligible to receive a special $5,000 signing bonus. Interested individuals looking to change careers and those who want to join an organization with great benefits, good salaries and ample overtime opportunities can learn more by visiting WorkAtMetroSTL.com.”
“Our Central Facility has approximately seven acres under one roof where we do the heavy lifting as it relates to maintenance, keeping our fleets out on the rails and on the streets, servicing our customers,” said Ron Forrest, Chief Operating Officer for Metro Transit. “We would be lost without our mechanics and our maintenance team. They’re continually thinking of new and better things for us to be more efficient and effective in our maintenance processes.”
“By creating discontinued and custom parts for our light rail and bus fleets in-house, we’re saving money, reducing downtime, and extending the lifespan of vehicles that serve thousands of riders every day,” said Taulby Roach, President and CEO of Bi-State Development.
