Metro Transit mechanics develop solutions leading to improved fleet performance, cost savings
More than $48,000 saved this past year by printing 3D replacement parts versus purchasing them
A view of the 3D printers at Metro Transit’s Central Facility.
From 3D printing critical parts to rebuilding transmissions and painting buses, 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 MetroBus, MetroLink 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 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 and also includes painting facilities and transmission overhaul.
One of the newest additions 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.
They have discovered tremendous cost savings using this new technology, as a replacement part that would normally cost several hundred dollars can be produced in-house for just a few dollars or less. 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.
A 3D-printed part.
From cup holders to air gauge covers and fuel caps to rubber bumpers, to date the agency has printed more than 7,500 parts in-house.
When they started using the 3D printers, the mechanics saw an opportunity to solve an issue for MetroBus operators. During extreme cold days, an air gap near the base of the steering column on the buses prevented operators from keeping their feet warm. A rubber seal available from the manufacturer to fix the problem costs more than $150 dollars each, and retrofitting 300+ buses this way would have been a significant expense.
“Our innovative mechanics went to work to solve the problem and produced a rubber steering wheel seal themselves at a fraction of the cost we would have to pay to purchase it from the manufacturer,” said Taulby Roach, president and CEO of Bi-State Development, which operates Metro Transit. “That solution alone helped to recoup almost the entire initial cost of the equipment within the first year of its use.”
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.
The transmission repair shop also plays a role in Metro Transit being recognized by the American Public Transit Association for its vehicle maintenance program, which has taken some of agency’s buses to one million miles. Metro is one of the few transit agencies that do in-house transmission rebuilds. The team does not use outside vendors and is able to control the quality of the product and components used in the rebuild process, so they can effectively replicate the performance of new transmissions.
A mentoring program in partnership with ATU will help to ensure the maintenance team continues to excel as new mechanics join the ranks. A mentor shows the mentee how to rebuild a transmission, the two work together to rebuild a transmission and then the mentee rebuilds a transmission under their mentor’s guidance.
“With our transmission program we have great relationships with our manufactures and talk regularly about the performance of specific parts,” said Roach. “We’ve been able to provide insight into solutions to improve these transmissions.”
The two paint booths at the Central Facility also have been outfitted with equipment and technology to enhance operations. The primary paint booth can accommodate a 60’ bus. The smaller paint booth is normally used for body panels and painting smaller components. An air operated man lift provides improved access.
The booths have a filtering system that creates a clean environment for the paint specialists painting the vehicles. The booths also function as a big oven, helping to bake the paint onto the vehicles and allowing the multicolor painting to be completed faster.
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.
Bi-State Development operates the Metro Transit system in the City of St. Louis and in St. Louis County in Missouri and in St. Clair County in Illinois.
Photos courtesy of Metro Transit/Bi-State Development.
Another view of the 3D printers at Metro Transit’s Central Facility.
About Metro Transit
Metro Transit operates the St. Louis region’s main public transportation system, which includes 24 battery electric buses and 237 clean-burning diesel buses that serve 58 MetroBus routes in eastern Missouri and southwestern Illinois. Metro also operates MetroLink light rail vehicles on 46 miles of track serving 38 stations in the two-state area, and operates Metro Call-A-Ride, a paratransit fleet of 123 vans. Metro Transit is a Bi-State Development enterprise.
