Inside BMW's Circular Economy: Old Materials Into New Parts

Описание: Turning old into new: Recycling as next step towards greater circular economy for BMW Group 3D printing. Inside BMW's Circular Economy: Old Materials Into New Parts

The BMW Group uses plastic wire (filament) and granulate from waste 3D printing powder and used parts to produce new components using the 3D printing technology. Waste powder generated from production of thousands of components each year and previously been disposed of, along with shredded used parts, is now processed into new filament. The filament is rolled onto spools like wire, which can then be used to print new items, such as auxiliary production devices and tools. This filament is used at the Additive Manufacturing Campus in Oberschleißheim, as well as at various sites across the BMW Group's global production network. In addition to recycled filament for the Fused Filament Fabrication (FFF) process, the Campus also provides recycled granulate for use in Fused Granulate Fabrication (FGF) technology, thus enabling manufacturing of large tools.

Additive Manufacturing Campus supports production sites with comprehensive package of recycled filament, printing parameters and expertise
As part of the BMW Group’s centre of competence concept, the Additive Manufacturing Campus facilitates the ongoing rollout of its in-house developed recycling filament. It enables locations by sharing expertise and providing comprehensive solutions. In collaboration with established and experienced 3D printing facilities at BMW Group production plants, suitable 3D printers are tested, and optimised printing parameters for the recycled filament are developed and validated for the respective models. This package – consisting of printer recommendations, recycled filament and validated parameter settings – is then made available to other plants. This ensures that locations are efficiently enabled and can quickly achieve high-quality printing results on site. The Campus provides further support by building know-how at the plants through relevant skills development and training opportunities. This includes foundational courses in 3D printing, advanced training on the topic of design for additive manufacturing and application-focused sessions on integrating 3D printing into the production environment. A strong and constantly evolving network has developed across the sites, benefiting from knowledge-sharing and mutual support. The next 3D printing facility, which is currently under construction at Plant Debrecen in Hungary, will benefit from the network’s experience and will support the new production plant for the Neue Klasse going forward.

3D printing at BMW Group production sites: proven driver of success
Installation and operation of 3D printers throughout the BMW Group's production network will ensure the successful implementation and continuous rollout of 3D printing technology. Thanks to rapid on-site response times, components can be available within just a few days – or even hours, in some cases. This enables short iteration loops and swift optimisations, helping prevent assembly line downtimes. The flexibility and design freedom of 3D printing spark creative ideas and solutions that can be developed and implemented directly by employees on the ground. Collaboration between the 3D printing facilities at the plants and the Additive Manufacturing Campus continuously drives further development of 3D printing and consistently leads to new applications and optimisations within the BMW Group’s production system.
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