With Pixels & Timber: Application of Mixed Reality for Human-Centered Train Design & Engineering

Abstract

Modern metro train design projects must balance evolving customer requirements, diverse stakeholder expectations, and the need for early, reliable engineering decisions. Conventional validation methods—document-based analyses, static CAD reviews, and late-stage physical mock‑ups—often reveal design issues too late, resulting in costly redesigns, schedule risks, and inefficient stakeholder involvement. To overcome these challenges, the Siemens Mobility project team developed an award‑winning Mixed Reality (MR) Human Factors (HF) and Customer Experience (CX) testing and validation approach—deployed in the ongoing Sydney Metro – Western Sydney Airport (SM-WSA) project—that merges physical prototyping with immersive Virtual Reality (VR) environments. The approach employs cost‑effective wooden or 3D‑printed structures augmented with a high-end Virtual Reality (VR) visualisation, enabling MR-based interactive evaluation of the train interior's user facing elements. This setup allowed rapid exploration of dozens of design variants and enabled evidence‑based design engineering decision making significantly earlier in the project. The method proved particularly effective for pre-validating a few design areas, such as stopping‑marker positioning, inclusivity & accessibility, and design options such as seat fabrics or headrests.The MR‑driven review workflow, combined with user performance- and behaviour-based system tests, demonstrated measurable benefits. First, evidence‑based Human Factors engineering became possible through precise spatial assessments using integrated haptic and visual feedback, enabling more confident design assurance and acceptance. Second, co‑creation and collaboration improved through intuitive, immersive engagements with train operators, accessibility committees, and end users, aligning with ISO 9241‑110 principles for human‑centred design. These sessions enhanced understanding, consensus-building, safety and engineering assurance and overall CX validation. Third, risk reduction and early design freeze were achieved by resolving issues before the high‑fidelity mock‑up stage, reducing Non‑Compliance Costs (NCCs), and preventing downstream costs from schedule disruptions.