The BMW Group has made a significant advancement in the field of additive manufacturing (AM) by integrating Wire Arc Additive Manufacturing (WAAM) technology into its series production process. This innovative approach enables the 3D printing of metallic vehicle components and tools that are not only lighter and stiffer than traditional die-cast parts, but also more sustainable, with lower energy consumption and reduced material waste.
At the Additive Manufacturing Campus in Oberschleißheim, BMW is harnessing WAAM technology from MX3D to produce a variety of components and tools. WAAM offers a notable advantage in terms of production speed, particularly for large components, with single welding seams enabling rapid manufacturing. This makes it especially suitable for components in the body, drive, and chassis areas, as well as for tools and devices.
The company’s Additive Manufacturing Campus serves as a dedicated hub for production, research, and training in the field of 3D printing. With over 30 years of experience in this technology, BMW has been focusing on the WAAM process since 2015 and has recently introduced a WAAM cell for test component production at the campus.
A key focus for BMW is the comparison of WAAM-produced components, such as a suspension strut support, with traditional series production parts made from aluminum pressure die-casting. Initial testing has shown that the WAAM process results in lower emissions during production, thanks to the lower weight of components and more efficient material usage. This offers a promising path towards more sustainable manufacturing in the automotive industry.
While WAAM components may have slightly rippled surfaces and require finishing in critical areas, BMW engineers have demonstrated that they can withstand high loads, including cyclical stresses, even without post-treatment. Optimized process parameters and robotic path planning are essential to ensuring durability directly from production.
Generative design, which utilizes algorithms to create optimized components based on specific requirements, is another area of focus for BMW. By employing generative design methods, the company can fully tap into the potential of WAAM technology, resulting in lighter, stiffer components that enhance vehicle dynamics and efficiency.
It is important to note that WAAM is not intended to replace other additive manufacturing processes, such as laser beam melting, but rather to complement them. Each process has its own advantages, with WAAM excelling in the production of larger components and offering a higher deposition rate.
Looking to the future, BMW plans to centralize the production of WAAM components in Oberschleißheim, with potential for expansion to other locations and collaboration with suppliers. The company also aims to explore the possibility of producing individual components directly on the assembly line using WAAM technology, and to increase the use of recycled metals for a more sustainable approach.
In conclusion, BMW’s adoption of WAAM technology represents a significant milestone in the automotive industry’s journey towards more sustainable and efficient manufacturing processes. With innovation driving the development of lighter, stronger, and more eco-friendly components, the future looks promising for additive manufacturing in the automotive sector.