BMW uses WAAM 3D printing to optimize derivative designs

BMW explained how to use WAAM (Arc Additive Manufacturing) starting from 2025 to manufacture lighter and stronger automotive components and reduce waste generation, in order to optimize the use of generative design tools.

The demonstrated WAAM process uses aluminum wire raw materials directly deposited through laser welding heads, enabling automotive companies to manufacture lighter and more robust parts than similar large parts.

BMW stated that in order to optimize the parts manufactured using this technology, the combination of manufacturing processes and general new component design is crucial. To this end, BMW is accelerating the use of generative design and working closely with interdisciplinary teams to develop its own algorithms, partially inspired by the natural evolution process.

Karol Virsik, Head of Vehicle Research at BMW Group, said, "What is impressive is how WAAM technology has evolved from research to a flexible tool that can be used not only for testing components, but also for mass production of components." "The use of generative design methods allows us to fully utilize design freedom, thus fully utilizing the potential of technology. Just a few years ago, this was unimaginable."

Although these components have wide welds, BMW engineers have proven that WAAM components can still be used for high loads without the need for precision machining of surfaces.

Since 2021, BMW has been testing this DED process at its additive manufacturing park in Oberschlei ß heim, Germany, where the first batch of components will be produced. BMW expects to increase production in other locations by using existing assembly lines with new software.

BMW stated that the adoption of WAAM technology will not replace SLS technology for more refined parts, but arc additive manufacturing technology is "superior" in terms of possible size and deposition rate of parts.

The company is even considering using WAAM technology to directly produce individual components on assembly lines, as this technology does not require new tools and only requires software changes to manufacture different components.

Source: NetEase Network