The BMW Group is increasingly relying on Wire Arc Additive Manufacturing (WAAM) at its Additive Manufacturing Campus in Oberschleißheim to produce metallic vehicle components and tools. The Oberschleißheim location integrates production, research, and training, reflecting the company's long-standing experience in additive manufacturing. Since 2015, the BMW Group has been researching the WAAM process there, and since 2021, a specialized WAAM cell has been in use for producing prototypes, such as a strut mount, which is then compared in numerous tests with conventional aluminum die-cast parts.
"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 due to their lower weight, favorable material utilization rate, and the possibility of using green electricity," reports Jens Ertel, Head of BMW Additive Manufacturing. The next steps towards production readiness include vehicle tests with WAAM-manufactured components, which are set to begin soon.
WAAM is particularly suitable for producing larger components and is already used for prototypes and small series production. It is ideally used in the production of parts for body, drivetrain, and chassis, as well as for tools and fixtures. Although the weld seams in the WAAM process result in slightly wavy surfaces that must be finished, tests show that the components can withstand high loads even without surface finishing. Optimized process parameters, which require precise coordination of welding processes and robot path planning, are crucial for the quality and durability of the parts.
Future Plans and Sustainability
Karol Virsik, Head of Vehicle Research at the BMW Group, is impressed with how quickly WAAM technology has evolved from a research tool into a flexible tool for not only experimental but also series components. "The use of generative design methods allows us to fully utilize the design freedom and potential of the technology, which was unimaginable just a few years ago," says Virsik.
The BMW Group plans to initially establish the WAAM production centrally in Oberschleißheim but also foresees an expansion to other locations and its use by suppliers. In the long term, the technology could even be used directly on the assembly line to produce different parts solely through software adjustments. Additionally, increased use of recycled metals could further enhance sustainability.
