- Steel and stainless steel
- Aluminium
- Titanium
- Composites
- Plastics

3D CAD Design

- 3D modelling
- Photo realistic rendering
- Joint design
- Design optimisation


- Hand analysis
- FE analysis
- Fatigue analysis

Systems Engineering

- Specifications
- Requirements
- Testing & verification
- Documentation

IP Protection

- Patent process
- Prior art
- Costs and benefits



Bid support for Chinese rolling stock manufacturer

We supported Chinese rolling stock manufacturer CNRCRC during the bid for 25 new High Capacity Metro Trains for Melbourne, especially in the technical area. Responsibilities included:

  • Review of tender documents prepared by the Chinese client to ensure they address the tender requests, are easily understood and written in good English
  • Explaining and interpreting western standards and specifications to the Chinese client
  • Suggesting technical solutions to meet requirements
  • Writing of tender response sections
  • Taking notes in meetings and telephone conferences

CNRCRC was one of the two remaining bidders. The feedback from the rolling stock client was that the technical tender response from CNRCRC was equivalent to the winning bid. CNRCRC’s price was slightly above the competition.

Locomotive crew cab rollover analysis

The latest revision of the Australian Standard applicable to locomotives introduced a rollover load case to protect the driver during a derailment.

Created a FE model of the existing crew cab and applied the rollover loads which included realistic simulation of the contact between crew cab roof and ground. The structural response is highly non-linear with large deformations and therefore non-linear solvers and material models were required.

Parts of the detailed FE model were also used to simulate a concrete block impacting the roof. This load case required a non-linear transient dynamic analysis as well as simulation of the contact between the concrete block and roof sheet as well as between different roof structural members. 


Composite Train Crew Cabin

Four upgraded power cars were required for the Sunlander tilt train which operates between Brisbane and Cairns. As part of the upgrade the crash management structure of the locomotives was aligned with current standards which in turn required a re-design of the composite crew cab.

Du to mass imbalances and mass restrictions it was necessary to make the crew cab as lightweight as possible whilst also meeting stringent object impact requirements to protect the driver.

In the impact area the crew cab was made from a fibreglass sandwich with aluminium honeycomb core. Fibreglass is reasonably tough and the aluminium honeycomb core crushes in the impact area absorbing significant amounts of energy.

The sides and non-impact critical areas of the crew cab were made from a carbon fibre sandwich with foam core to minimise weight. As well as this many separate steel components were incorporated into the composite shell further reducing mass and the number of parts required.

Responsibilities included the design and impact testing of the sandwich structure as well as selecting the supplier. Noteworthy is that the first batch of impact test panels successfully stopped the projectile making further tests unnecessary.

The crew cab was manufactured from 3D files by PCT in Dubai and assembled to the train in Maryborough. The manufacturer used the 3D files to directly CNC mill the patterns for the moulds. 


Aluminium composite floor panels

The floor panels of the Waratah Train are manufactured from aluminium skins separated by a bonded aluminium honeycomb core. The upper deck floor has aluminium extrusions embedded to allow mounting of the seats to the floor.

The upper deck floor is the largest part of the train and spans the whole width and length of the upper deck saloon. Using aluminium sandwich construction allows for a lightweight and stiff construction without requiring any additional support structure. This in turn minimises the depth of the floor and provides maximum possible headroom for the passengers.

Similar to the roof frames and hatches the scope included the whole product design cycle from writing the specification, liaising with the supplier, design and analysis to supplier selection.

The upper deck floor was manufactured by Euro - Composites in Lichtenstein and shipped to China where it was installed into the train.

Less complex lower and vestibule saloon floor panels were manufactured in China and bonded to the steel structure of the train.


Stainless steel roof frame and hatches

The stainless steel roof frames of the Waratah Train support various traction equipment supplied by Hitachi. The equipment is protected by opening hatches to allow maintenance access.

Responsibilities included writing of the specification, liaising with Hitachi to coordinate interface requirements, design of the frames and hatches, verification of the design via FE analysis and supplier selection.

The frames and hatches were manufactured in Sydney by CBSM and installed to the trains in Newcastle where the traction equipment was also fitted.