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 the day-to-day operations of the St. Louis region’s primary transit agency. 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.
“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.”
Approximately 60 mechanics are employed at the Central Facility, which serves as Metro Transit’s main repair 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. One of the newest additions at the Central Facility is 3D printing capabilities for manufacturing that have proven to be a real game changer. Purchased in 2024, the 3D printers 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.
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.
To help provide context for the savings, the 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. To better understand the improvements being delivered, a redesigned traction motor cover, for example, adds a lip to prevent water intrusion into wire connections, improving long-term reliability for the rail fleet. The team also created a 3D printed replica of the light rail vehicles’ dashboard for operators to sit at and provide feedback on the ergonomics of the new LRV 5 dashboard design.
Metro’s $51,200 investment has already paid off—saving over $48,000 by printing replacement parts in house vs purchasing them from the manufacturer, and thousands more by printing creative new custom items to address evolving needs. To date the agency has printed more than 7,500 parts in-house.
“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, which operates Metro Transit.
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 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 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.