Article: Full-Fleet Supply of Dashcam Mounting Brackets
Overview
KeolisAmey Metrolink required a practical interim solution to supplement the existing forward-facing CCTV system on the Manchester Metrolink tram fleet. To maintain visibility and support ongoing operations, the operator planned to introduce a temporary dashcam arrangement while a longer-term CCTV replacement was developed.
Following a successful trial of an initial 3D-printed dashcam bracket, DB ESG was engaged to help turn the concept into a robust full-fleet solution. Our role included supporting the design for manufacture, carrying out the necessary assessments and supplying the brackets to enable a safe and efficient rollout across the fleet.
Scope of Work
- The most suitable manufacturing approach for 300 dashcam brackets was assessed, with injection moulding identified as the most effective option for reliable, repeatable production at scale.
- The original 3D bracket model was refined to suit injection moulding, ensuring the final design was ready for manufacture and aligned with the required compliance checks.
- The required fire compliance assessment was completed to confirm the bracket design met relevant railway safety requirements.
- A structural assessment was also carried out to verify the mounting bracket was suitable for use in service.
- A total of 300 polycarbonate brackets were manufactured to support fleet-wide rollout.
- A First Article Inspection (FAI) report was completed to support product verification ahead of fleet-wide implementation.
Results
By supporting the development, assessment and manufacture of the new mounting brackets, DB ESG helped KeolisAmey Metrolink implement a practical interim solution quickly and with confidence. The project supported continued fleet operation and service continuity while a permanent CCTV replacement was progressed.
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