3
D Printing has quickly become one
of the fastest embraced
manufacturing and prototyping
innovations throughout the automotive
industry. Recently, it has been utilized to
manufacture engine parts, a replica of
historical race cars, customized exhaust
systems and even whole street prepared
cars. While 3D printing is not another
innovation by any methods, it is just in
the last half-decade that it has begun to
be plainly received by a large portion of
the automobile industry. However, not
everyone currently is jumping on the 3D
printing fad; a few organizations can be
considered pioneers and have been using
it for decades.
German automobile giant, BMW Group
was one of the earlier adopters of 3D
printing and additive manufacturing
technology. When they opened their
Rapid Technologies Center in 1990, the
firm essentially used their stereo
lithography machine to 3D print early
ideas and part models. The parts would
frequently be used as a proof of concept
before they proceeded onward to
traditional tooling, or be used for model
vehicles. In the beginning, the additively
produced parts were mostly used for
concept cars but were further developed
for additional purposes over the years.
Depending on the component
specifications, BMW Group applies
different procedures and materials. Be
that as it may, as per BMW, those early
positive experiences wit h 3D printing for
a quarter of a century helped shaped how
the organization used 3D printing today,
and how they will be using it later on.
Refining Additive Manufacturing
Processes
The BMW Group is in constant work of
refining additive manufacturing
processes for series production.
Dominating the conventional point-to-
point 3D printing methods, the new,
planar printing technologies enable
considerably faster production times, and
go above and beyond to ease the printing
process. Beamers or infrared sources are
used to expose the full surface, rather
than point-to-point, high-priced light
sources, such CO2 or UV lasers.
| August 2017 |
Dr. Jens Ertel, head of the BMW Group’s
Additive Manufacturing Centre says,
“Planar technologies are central to the
use of additive processes in series
production. The most recent example can
be found in the preliminary trials of the
HP Multi Jet Fusion technology. The
process will initially be used in
prototyping, but we plan to extend it into
series production over the long term.”
The process utilizes print heads and
liquid agents, like a conventional inkjet
printer.
At the start of the process, a thin layer of
base powder material is applied. The
print head then sprays fusing and
detailing agents onto the powder bed.
What is unusual is that at the same time,
the respective layer of the component is
fused using infrared radiation. This
speeds up production time and increases
flexibility.
Using CLIP Technology to its Fullest
Potential
Last year saw the introduction of CLIP
technology (Continuous Liquid Interface
Production) – a breakthrough in the field
of planar 3D printing process. Since this
method works with planar exposure from
a beamer, it shortens production times
considerably. The BMW Group used the
process for the first time to produce
individualized side indicators for the
“DriveNow” car-sharing fleet. In a social
media campaign, German customers
voted on names for a total of 100 MINIs
in the fleet. CLIP technology was then
used to integrate these in the indicator
body of the vehicles being tested on the
roads in Germany.
The Additive Manufacturing Centre at
the company’s Research and Innovation
Centre (FIZ) has also been using these
forming processes to produce parts for
the new Rolls-Royce Dawn since the
start of the year. The team at the FIZ
handles nearly 25,000 prototype orders
annually and delivers more than 100,000
components per year to customers within
the BMW Group. The spectrum ranges
from small plastic holders to design
samples to metal chassis components for
functional testing. Depending on the
process used and size of the parts,
components are often available within
just a few days.
Decades of Experience Helping
Overcome Every Hurdle
With more than a quarter of a century
usage, many areas have enjoyed the
benefits of additively-manufactured
components from BMW Group. Classic
examples of additive manufacturing are
areas where customized and, in some
cases, highly complex components are
required in small quantities – mainly in
pre-development, vehicle validation and
testing or for concept and show cars, but
also small series production. Along these
lines, the company is constantly working
to harness new additive methods for
vehicles from prototypes to classic cars.
However, the methods are also utilized in
tool-making and manufacturing
equipment. The BMW Group celebrated
the first successful use of this technology
in small-series production in 2010, with
the additively-manufactured water pump
wheel still fitted in Deutsche
Tourenwagen Masters (DTM) vehicles to
this day.
Expanding its Pioneering Role into the
Future
The BMW Group is bit by bit pursuing
the evolution and use of advanced
additive-manufacturing methods. The
BMW Group is confident that planar 3D
printing technologies will enable much
faster production times and more
economical production in the future and
the company aims to continue expanding
this pioneering role in the future.
About the Key Executive
Dr.-Ing. Udo Hänle, is Senior Vice
President, Production Strategy and
Technical Integration at BMW Group.
Born in Friedrichshafen/Bodensee, Dr.
Udo completed his studies and master
degree in Aerospace Engineering, from
the University of Stuttgart. From the
same university, he later got his Ph.D.
Since then, he has been at forefront of
BMW Group, performing every role he
was given to successfully. At his current
role, he looks after production strategy
and technical integration at BMW.
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