The new face of passenger trains – modern rail vehicle front sections and cladding.

Nowadays, a passenger train is more than just a means of transport. Today, a train or tram is part of the modern landscape, a showcase for the operator, a symbol of innovation and, increasingly, the practical implementation of sustainable development. In this context, the design of rail vehicle external components is not only a matter of aesthetics but is also a matter of advanced engineering and safety at a high European standards level.

Norms and standards in the foreground

Although the exterior of a vehicle is primarily associated with its appearance, in reality, every curve, crease or angle translates into specific technical parameters: air resistance, noise level, energy consumption, structural strength and crash safety.

Therefore, when designing the front or side panel cover of a rail vehicle, engineers must take into account several structural design requirements and formal requirements that result from the norms and standards in force in the European Union. For a given project, these can include e.g.:

• TSI LOC&PAS – Technical Specifications for Interoperability for locomotives and passenger vehicles which define requirements for car body structure design as well as for safety and compatibility with infrastructure;
• EN 12663 – a standard that describes the design and strength requirements for rail vehicle bodies, such as passenger load capacity, stiffness and resistance to exceptional loads and dynamic operating loads;
• EN 13749 – standard for the design and strength assessment of bogies for rail vehicles, particularly concerning fatigue life and dynamic loads;
• EN 15085 – standard for the welding of rail vehicles and their components, which has crucial meaning for the safety of welded part joints;
• EN 15227 – standard with requirements that provide passive safety (crashworthiness), including collision scenarios and minimum energy values to be absorbed by the structure;
• EN 17149 – standard with a procedure for assessing the strength of rail vehicle structures;
• EN 45545 – standard regarding fire protection of materials used in rail vehicles, including external components;
• VDV 152 – recommendations for the design of trams and light rail vehicles, including criteria for infrastructure and passenger safety compatibility and car body design compatibility;
• DVS 1612 – guidelines that specify requirements for the quality of design and manufacturing of welded thin-walled steel structures, typical for rail vehicles, in particular, in terms of fatigue life and weld quality control;
• DVS 1608 – guidelines that describe procedures and requirements for the design of thin-walled structures made of light aluminum alloys, in particular, with regard to welding methods and to strength assessment of such joints in rail vehicles;
• VDI 2230 – guidelines for calculation of highly loaded bolt joints which are frequently being used in rail structures, where durability, safety and reliability of mechanical assembling have crucial meaning.

Such detailed and multi-aspect regulations mean that the design process of external components for rail vehicles requires not only technical knowledge but also proficiency in interpreting standards, often confirmed by special certificates. The external appearance of a train is not just a matter of aesthetics – it is primarily a question of safety, durability and compliance with operational requirements. Therefore, engineers should take these aspects into account at the earliest stage of the design process – from the initial sketches (styling, CAD) through computational analyses (strength, CAE) to material and technology selection decisions.

Aerodynamics, aesthetics and branding

The front of a train is its most recognised part. This is where the attention of passengers and infrastructure users is focused on. That is why, in the era of modern transport, more and more companies see the external appearance of their rail vehicle as part of their brand identity. A distinctive shape, styling details, lighting elements and colors – all these factors influence brand recognition and perception of the rolling stock as modern.

However, in addition to aesthetics, the appearance of the front of a train has key technical importance: a streamlined shape can reduce air resistance by up to several percent. This translates into real energy savings and improved ride comfort thanks to reduced noise, vibrations and turbulence.

The contemporary approach to vehicle front design increasingly combines functionality with innovative trends in engineering and design, such as:

• biomimicry and aerodynamics inspired by nature – e.g. lines reminiscent of an owl’s or dolphin’s beak reduce air resistance and noise levels, e.g. in tunnels.
• integration of smart technologies – external (tracking) cameras, active cooling flaps, radar systems – all of which require adequate space and structural protection.
• modularity and unification – limit the number of design variants in favour of components common to many models, which reduces production, storage, and servicing costs.
• passive safety – crumple zones, energy absorbers and structural reinforcements minimize the possible accidents or damage effects, they must be carefully integrated into the front end without compromising visual appeal.
• visual identification – transport operators increasingly expect to possibly ‘personalize’ the front of the vehicle so that, for example, different lines (regional, urban, international) can be distinguished by styling while retaining the basic technological platform.

The number of standards that must be met, combined with current and upcoming trends, make train design a complex process where aesthetics is combined with functionality and with concern about passenger comfort and well-being. As a result, a well-designed vehicle front becomes not only its calling card, but also a real source of operational and economic advantages.

Materials of the future: lightweight, durable and environment friendly

When designing exterior components, engineers must bear in mind that modern panelling should not only be aerodynamic, but also lightweight, weather-resistant and safe. For this reason, the following materials are increasingly being used:

• aluminium and its alloys – lightweight, corrosion-resistant and well suited for welding (in accordance with EN 15085),
• composite materials, ideal for forming crumple zones in accordance with EN 15227,
• modern structural adhesives, which support integrity and aesthetics, but also eliminate welds and reduce the risk of dangerous cracks.

The selection of suitable construction materials is becoming a key element of the design process – it affects not only the external appearance of the vehicle, but also its durability, safety, weight and ease of production.

Support from modern engineering

In today’s railway industry, the time it takes to implement a project is just as important as its quality. But how do you design the front and body of a vehicle so that it meets strict requirements with a minimum number of iterations? The key lies in the competence of the design team and in the use of the right engineering tools.

Solutions that are key to the design of such components include engineering analyses (CAE). In the case of trains, they allow to:

• optimise the design in terms of strength and weight (in accordance with EN 12663),
• analyse the behaviour of the structure in collisions (in accordance with EN 15227),
• optimise the topology and geometric parameters,
• improve passenger and driver comfort through acoustic and thermal analyses (in accordance with EN 14750 and EN 14813),
• identify potential weak points before real prototyping phase.

CAE analyses make it possible to significantly shorten the design cycle, reduce costs, and adapt the design to both operational requirements and aesthetic expectations. It is a tool that supports conscious decisions in the earliest stages of the project.

What does the future hold?

The development directions in the rail industry are clearly outlined today: automation, greening, and digitalisation. They are shaping new expectations for exterior design, which must keep pace with the growing complexity of technology, and support it at the same time.

In the coming years, we can expect that:

• trains will become even lighter and more energy-efficient thanks to the use of modern materials, hybrid structures and optimised aerodynamics,
• maximum speeds will continue to increase, which means that the front of the vehicle and the entire bodywork will have to meet increasingly stringent aerodynamic and strength requirements, while maintaining low noise and vibration levels,
• crumple zones will be developed using digital twins and advanced crash analyses, which will increase safety without the need for excessive structural reinforcement,
• visual identity will take on new meaning, especially for autonomous and urban transport, which will become part of intelligent mobility systems, and their appearance will be one of the key points of contact with the user.

Exterior design is becoming an integral part of technology, influencing the visual perception, efficiency, safety and future scalability of transport solutions.

Between engineering and travel experience

Today, the design of external elements of rail vehicles is a process that combines engineering, aerodynamics, safety standards, aesthetics, and visual identity. Every curve, crease,e and material detail is the result of hundreds of decisions based on data, regulations, certifications, the experience of the design team, and modern engineering tools.

In an age of increasing speeds, automation, and ecology, the exterior appearance becomes both a ‘protective shield’ and a showcase. It creates the first impression and has a real impact on the efficiency and experience of travel.

At Endego, we support rolling stock manufacturers in a wide range of rail vehicle design and optimisation.

• Modernization of the front structure of electric multiple units
• Optimization of the structure of the locomotive
• Jazz Duo and Krakowiak tram bodies
• Strength analysis of a coal wagon structure

📩 Contact us to discuss your project.