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BMW Opens €15 Million Additive Manufacturing Campus

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Quick Answer: What is BMW’s Additive Manufacturing Campus?

BMW Group’s €15 million Additive Manufacturing Campus, opened in 2020, is a state-of-the-art facility that centralizes 3D printing for research, prototyping, and series parts production. Located in Munich, the campus employs 80 workers operating approximately 50 industrial additive manufacturing systems. The facility houses the IDAM (Industrialisation and Digitisation of Additive Manufacturing for Automotive Series Production) project and POLYLINE consortium, aiming to automate 3D printing processes and reduce manufacturing costs by up to 50%. BMW, which has been using 3D printing for nearly 30 years and produced over 300,000 parts in 2019, aims to use this campus to industrialize 3D printing for mainstream automotive production. [1]

Introduction: BMW’s €15 Million Investment in 3D Printing’s Future

BMW Group has opened its new Additive Manufacturing Campus, which combines 3D printing for research, prototyping and series parts production in a single facility. The €15 million investment is meant to further the vehicle giant’s position in the use of additive manufacturing (AM) for the automotive industry. [2]

At the ribbon-cutting ceremony, Milan Nedeljković, BMW AG Board Member for Production, said, “Additive manufacturing is already an integral part of our worldwide production system today, and established in our digitalisation strategy. In the future, new technologies of this kind will shorten production times even further and allow us to benefit even more fully from the potential of toolless manufacturing.” [3]

The Facility: Scale, Capabilities, and Personnel

In 2019, BMW Group 3D printed roughly 300,000 parts. The Additive Manufacturing Campus employs 80 workers running about 50 industrial AM systems, including metals and plastics. Beyond the center, BMW runs 50 other 3D printers globally. This centralized approach represents a strategic shift from distributed operations to a unified hub for additive manufacturing excellence. [4]

The campus features multiple specialized zones including a pre-development team dedicated to improving new technologies and materials for use throughout BMW, with a focus on automating process chains. By reducing manual labor, the unit aims to reduce the cost of 3D printing and make it better suited for industrial scale. The facility also includes training areas where workers from throughout BMW Group can learn about AM technologies and methodologies. [5]

Table 1: BMW Additive Manufacturing Campus Key Specifications
Specification Details
Investment €15 million
Location Munich, Germany
Employees 80 workers
AM Systems 50 industrial systems
Materials Metals and plastics
Annual Production (2019) ~300,000 parts

The IDAM Project: Industrializing Additive Manufacturing

An example of the BMW Group’s work in this area is the Industrialisation and Digitisation of Additive Manufacturing for Automotive Series Production (IDAM) project, funded in part by the German Ministry of Education and Research. With the IDAM project, a production line, from production preparation to manufacturing and reworking of parts, is being established at the Additive Manufacturing Campus. [6]

The IDAM consortium includes 12 partners from industry and research, including BMW, automotive supplier GKN Additive, and several technology companies. The project aims to create a fully automated production line capable of manufacturing 50,000 series parts annually with 3D printing, including more than 10,000 individual and spare components. This represents a ten-fold increase over previous 3D printing production volumes. [7]

The project focuses on integrating all process steps into a digital workflow, from design through post-processing and quality assurance. Key innovations include automated powder handling, build plate management, and part removal systems. By reducing human intervention and standardizing processes, IDAM aims to make AM competitive with traditional manufacturing for mid-volume production runs. [8]

The POLYLINE Project: Digital Process Chains for Plastics

Also at the campus, BMW will be performing its work in the POLYLINE project, in which process steps for the series production of plastic parts are connected digitally and a quality assurance strategy is developed to ensure consistent quality throughout the process chain. [9]

The 15 members of the POLYLINE consortium will use the facility to create and test what they consider a “future-proof” automated production line for 3D printing plastic parts that is digitally linked. The consortium includes major automotive suppliers, research institutions, and technology companies. So far, the project members suggest that, through this work, manufacturing costs can be cut by 50 percent, while improving the stability of 3D printing and sustainability of production overall. [10]

POLYLINE focuses specifically on Multi Jet Fusion (MJF) technology from HP, which BMW uses for certain plastic parts. The project aims to create a connected workflow from design through post-processing, with real-time quality monitoring and automated process adjustments. This digital approach aims to reduce scrap rates and improve repeatability for series production. [11]

Table 2: BMW Additive Manufacturing Projects Comparison
Project IDAM POLYLINE
Focus Metal parts automation Plastic parts digital workflow
Partners 12 consortium members 15 consortium members
Annual Target 50,000 parts Cost reduction 50%
Technology Metal powder bed fusion HP Multi Jet Fusion
Key Innovation Automated powder handling Real-time quality monitoring

BMW’s 30-Year History with 3D Printing

BMW has been involved in 3D printing for nearly 30 years, first prototyping parts for concept cars in 1991 before using AM for small series production in 2010. The company began with stereolithography (SLA) and selective laser sintering (SLS) technologies for rapid prototyping. These early efforts were limited to design validation and concept vehicle development. [12]

In 2010, BMW made a significant shift by using metal powder bed fusion to 3D print water pump wheels for DTM (Deutsche Tourenwagen Masters) race cars. This was one of the first applications of metal 3D printing for automotive series production, albeit in the high-performance racing segment. The water pump wheels demonstrated that 3D printed parts could withstand the rigorous demands of professional motorsport. [13]

Since then, the company has 3D printed parts for the Rolls-Royce Phantom, BMW i8 Roadster, and MINI John Cooper Works GP. The Rolls-Royce Phantom features decorative AM components, while the BMW i8 Roadster uses 3D printed roof brackets. The MINI John Cooper Works GP is particularly notable as a vehicle that features four 3D-printed components standard, representing one of the most extensive uses of AM in a production vehicle. [14]

BMW’s AM applications have evolved from prototyping to functional end-use parts, particularly in low-volume segments like luxury and performance vehicles. The company has explored various applications including custom accessories, spare parts for older models, and production tooling. In 2018, BMW announced that it had produced its one-millionth 3D printed part, marking a significant milestone in the company’s additive manufacturing journey. [15]

Strategic Investments: BMW i Ventures and Technology Partners

In addition to part production, the corporation has been investing in new AM technologies via its venture capital arm, BMW i Ventures. In 2016, the division funded Carbon’s Digital Light Synthesis for continuous digital light processing. Carbon’s technology, originally developed for consumer goods applications, offered potential for automotive parts due to its speed and surface quality. [16]

The next year, BMW i Ventures contributed to Desktop Metal, which has since released metal binder jetting, bound metal deposition and carbon fiber 3D printing systems. Desktop Metal’s binder jetting technology is particularly relevant to BMW’s goals of scaling up production, as it offers faster build speeds compared to powder bed fusion while maintaining quality suitable for functional parts. [17]

Other investments have gone to digital manufacturing platform Xometry and German startup ELISE, dedicated to automating product design. Xometry operates a distributed manufacturing network that could help BMW scale production capacity without major capital investments. ELISE, founded by former BMW employees, offers software that automatically optimizes parts for additive manufacturing. [18]

The company can purportedly save up to 90 percent in design time by producing part “DNA” that encompasses such information as technical and load requirements, as well as manufacturing restrictions, optimization parameters and costs. The DNA can be used to then automatically create optimized parts. This approach aligns with BMW’s goals of integrating AM throughout its engineering and production processes. [19]

BMW vs Other Automakers: The Competitive Landscape

BMW is not alone in its pursuit of additive manufacturing capabilities, but its approach differs from many competitors. While companies like Volkswagen, Audi, and General Motors have invested in 3D printing, BMW stands out for its centralized campus approach and focus on automation for series production. Most competitors still use AM primarily for prototyping or limited production runs. [20]

German automotive competitors have also made significant investments. Audi, for example, operates its own 3D printing center in Ingolstadt, focusing on metal parts for tooling and prototype production. Daimler (Mercedes-Benz) has explored 3D printing for truck spare parts and custom components. Porsche has used metal 3D printing to recreate parts for classic cars that are no longer available. [21]

Beyond Germany, Volkswagen has been researching 3D printing for mass production, including experiments with binder jetting technology. General Motors has partnered with Autodesk on generative design for seat brackets and other structural components. Ford has made significant investments in Carbon’s technology and operates a dedicated AM facility in Dearborn, Michigan. [22]

What sets BMW apart is the scale of its production (300,000+ parts annually) and the level of integration into its production network. The €15 million investment in the Additive Manufacturing Campus demonstrates BMW’s commitment to making AM a core manufacturing technology rather than a niche capability. The company’s participation in IDAM and POLYLINE, both publicly-funded projects with multiple partners, shows BMW’s willingness to collaborate on industry-wide challenges. [23]

Future Outlook: From Luxury to Mainstream

All of this is directed toward BMW’s larger goals for AM and automation, which Daniel Schäfer, Senior Vice President for Production Integration and Pilot Plant at the BMW Group, spoke to: “Our goal is to industrialise 3D printing methods more and more for automotive production, and to implement new automation concepts in the process chain. This will allow us to streamline component manufacturing for series production and speed up development. At the same time, we are collaborating with vehicle development, component production, purchasing and the supplier network, as well as various other areas of the company to systematically integrate the technology and utilise it effectively.” [24]

The challenges for mainstream adoption remain significant. See also: Best Budget 3D Printer Upgrades That Actually Impr…. Cost per part, while decreasing, is still higher than traditional manufacturing for many components. Build speed and material options need to expand to meet automotive requirements. Quality assurance and certification processes for safety-critical parts require rigorous development. BMW’s investments in automation and digital workflows are directly addressing these challenges. [25]

As described here, BMW has demonstrated expert use of the technology, just as one would expect. When it comes to series production, so far 3D printing has been limited to luxury and sports vehicles. Given its experience and expertise, however, it seems relatively safe to assume that it will be among those pushing series production of AM to more mainstream product lines. By reducing costs through the projects described above and by adopting newer technologies designed for large batch production, we may ultimately see 3D-printed end parts make it into products that the average consumer might interact with. [26]

Potential future applications include custom interior trim tailored to individual customer preferences, lightweight structural components for electric vehicles, on-demand spare parts for dealerships, and production tooling that can be updated faster than traditional tooling. As BMW’s capabilities expand, these applications could move from experimental to standard practice. [27]

Frequently Asked Questions

1. What is the purpose of BMW’s Additive Manufacturing Campus?

The €15 million Additive Manufacturing Campus serves as a centralized facility for BMW’s 3D printing operations, combining research, prototyping, and series parts production. The campus houses major projects like IDAM and POLYLINE, aiming to automate 3D printing processes, reduce manufacturing costs by up to 50%, and industrialize additive manufacturing for mainstream automotive production. It employs 80 workers operating 50 industrial AM systems and serves as a hub for training and technology development. [28]

2. How many 3D printed parts does BMW produce annually?

In 2019, BMW Group produced approximately 300,000 3D printed parts. With the new Additive Manufacturing Campus and projects like IDAM targeting 50,000 series parts annually, the company aims to scale this production significantly. The total production includes parts for prototype vehicles, series production components for luxury models, custom accessories, and spare parts. [29]

3. What 3D printing technologies does BMW use?

BMW employs multiple additive manufacturing technologies including metal powder bed fusion (for parts like water pump wheels and structural components), HP Multi Jet Fusion (for plastic parts), and various polymer 3D printing methods. The company has invested in binder jetting technology through Desktop Metal and continues to evaluate new systems through BMW i Ventures. Technologies are selected based on material requirements, production volume, and performance specifications for each application. [30]

4. Which BMW vehicles feature 3D printed parts?

BMW has incorporated 3D printed parts into several vehicles including the Rolls-Royce Phantom (decorative components), BMW i8 Roadster (roof brackets), and MINI John Cooper Works GP (four standard components). The company has also produced parts for DTM race cars (water pump wheels) and various concept vehicles. Current applications focus on low-volume luxury and performance models, but future plans aim to expand to mainstream production vehicles. [31]

5. How does BMW compare to other automakers in 3D printing adoption?

BMW is among the leaders in automotive additive manufacturing, distinguished by its large-scale production (300,000+ parts annually), centralized campus approach, and focus on automation for series production. While competitors like Audi, Daimler, Porsche, Volkswagen, GM, and Ford have also invested in 3D printing, most use it primarily for prototyping or limited production. BMW’s participation in major collaborative projects (IDAM, POLYLINE) and its €15 million investment in dedicated infrastructure demonstrate a deeper commitment to industrializing AM. [32]

6. What are the IDAM and POLYLINE projects?

IDAM (Industrialisation and Digitisation of Additive Manufacturing for Automotive Series Production) is a project focused on automating metal 3D printing processes, targeting 50,000 parts annually with a fully automated production line. POLYLINE connects process steps for plastic parts production digitally, aiming to cut manufacturing costs by 50% while improving quality and sustainability. Both projects involve multi-company consortia and are partially funded by the German government, reflecting a collaborative approach to advancing AM technology for automotive applications. [33]

7. How is BMW reducing the cost of 3D printing?

BMW is reducing costs through multiple strategies: automating manual processes (IDAM project), creating digital process chains (POLYLINE project), investing in faster technologies like binder jetting (Desktop Metal), and scaling production volumes to achieve economies of scale. The company also uses software tools like ELISE to optimize designs for additive manufacturing, reducing material usage and print time. These combined efforts aim to make 3D printing competitive with traditional manufacturing for mid-volume production runs. [34]

Related: BMW 3D Printing Production Process | Additive Manufacturing | Mega Factories · Covestro Buys DSM Additive Manufacturing: Analysis and Implications for 3D Print · Virtual AM Medical Event: From Innovations to the Future of Additive Manufacturi

References

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