Source: www.press.bmwgroup.com/article
Pictures: BMW Group

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MX3D is proud to share that BMW Group employed their M1 Metal AM System and proprietary software MetalXL to 3D print automotive components.

BMW Group demonstrates how additive manufacturing, specifically wire arc additive manufacturing (WAAM), can provide valuable solutions for an industry such as automotive. Their engineers succeeded in proving that it is possible to produce high-quality serial metal components using WAAM.

In their official Press Release, BMW Group mentioned how their components have passed tests to confirm the strength and consistent quality without the requirement of complete post-processing of the surface: “…the BMW Group engineers were able to show that WAAM components can be used for high, including cyclic, loads even without post-treatment of the surface. To ensure durability directly from production, optimized process parameters are crucial: the combination of welding process and robot path planning must be optimally coordinated.”

With more than 30 years of experience in additive manufacturing, BMW Group has been a pioneer in the field of additive manufacturing. Since their engineers started working with WAAM processes, they discovered that WAAM technology could lead them to lower emissions in the production process and reduce material usage, while at the same time maintaining a cost-effective and efficient production.

Furthermore, BMW Group states that since 2021, a WAAM system has been used for the production of test components. One of these example applications is a suspension strut support, which is compared with the die-cast aluminum component series in extensive test runs on the test bench. “Even in this early phase of technology enablement, it is clear that the WAAM process can lead to lower emissions in the production process. The components can be produced more efficiently thanks to their lower weight, low material usage rate and the possibility of green electricity,” reports Jens Ertel, Head of BMW Additive Manufacturing. They state that “the next development step on the way to series production is testing components in the vehicle, which will begin in the foreseeable future”.

MX3D congratulates BMW Group for their achievements and is looking forward to the upcoming implementation of WAAM in its production process.

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“BMW is pushing the boundaries for vehicle design and production with the WAAM technology, and it is amazing to see MX3D’s system and software have had a significant role in their exploration and manufacturing of components. It shows MX3D’s technology’s advantages like maximum design freedom to reduce part weight and 24/7 production capability to fit the automotive industry. BMW’s target of testing vehicles with WAAM components by 2025 will be another significant milestone for our technology, and we are very excited about it.”

Thomas Van Glabeke – Chief Product Officer at MX3D