X’Trapolis 2.0 & G-Class Tram Jigs & Fixtures Supply

Alstom, a global leader in innovative railway technology, undertook the assembly of new trains and trams in
Melbourne. Their primary objective was to ensure the highest levels of safety for both passengers and workers
involved in the project. Given the complexity and scale of the assembly, Alstom sought partners to engineer and
manufacture specialised jigs and fixtures to support their large-scale operations.

Tram and train assembly demands absolute precision, as all components must be perfectly aligned to meet stringent operational safety and performance standards. Copamate was engaged to design and manufacture custom jigs and fixtures tailored to Alstom’s requirements. These jigs and fixtures are all manufactured utilising in-house capabilities such as fabrication, precision machining, painting and assembly. Copamate has engineered over 100 different types of jigs and fixtures ranging in different shapes and sizes.

One example of Copamate’s manufactured jig and fixtures was the
BM1-7 H-Frames

The BM1-7 H-Frame is a jig and fixture engineered to securely support subassemblies during critical manufacturing processes. It ensures precise positioning of the frame, enabling accurate welding, assembly, and the integration of components such as wiring, exterior panels, and other structural elements.

Copamate’s involvement in the NGT program so far has been a resounding success. The project’s key outcomes included:

• Improved Assembly: Copamate’s jigs and fixtures provided Alstom with a safe way for trams to be assembled. This was achieved through a robust jig and fixture design that reduces the risk of misalignment, ensuring the tram remains securely in place during the assembly process.

• Improved Efficiency: The H-Frame facilitated smoother workflows by reducing the need for manual adjustments and rework. Its precision engineering allowed Alstom to streamline the assembly process, saving time and ensuring consistent results.

• Enhanced Worker Safety: By securely holding subassemblies in place, the H-Frame minimised the risk of accidents associated with unstable components during assembly. This contributed to a safer working environment for Alstom’s team.