BMW 3D printed parts in batches to realize the systematic integration of product development and manufacturing

The systematic integration of product development and manufacturing is carried out through generative design3D printing-Additive manufacturing component development, through artificial intelligence to identify suitable components, all this is not the future, but has become a reality.pass throughBMW GroupIndustrialized by the new Rolls-Royce Ghost3D printingComponents to appreciate what the future has come3D printingIndustrialization.

BMW Group will3D printingIndustrialization of technology

Simulation improves the freedom of design and manufacturing

According to from Munich, GermanyBMW GroupThe latest news on December 3, 2020, the BMW Group is moving towards industrial3D printingThe system integration of the process takes the next step. As the 3D Science Valley in “Build a car3D printingFor the production line, how is the development of the IDAM project led by BMW?As mentioned in the article, IDAM initiated by BMW aims to pave the way for additive manufacturing to enter the industrialized mass production of automotive applications, and to lay an important cornerstone for Germany’s status as a manufacturing power in the next industrial revolution.

With the fruitful implementation of the project, BMW has now achieved phased success.This mainly includes3D printing-Additive manufacturing technology is used in the development and production of vehicles.The BMW Group wants to make the most of3D printingThe advantages of technology-such as rapid availability of components, the realization of innovative design and flexibility in manufacturing.

According to Daniel Schäfer, head of the BMW Group’s production integration and pilot plant, additive manufacturing helps the BMW Group speed up the product development cycle, allowing vehicle development to reach series maturity faster.With the help of3D printing, The production time of the components is also shorter, and at the same time it can meet the high quality requirements.

Rolls Royce3D printingComponent

Since mid-2020, the BMW Group has been approving new Rolls-Royce Ghost models3D printing-Additive manufacturing technology produces metal and plastic auto parts. These parts are manufactured at different locations in BMW’s global production network along the process chain and assembled in Goodwood, UK.The company will install hundreds of thousands in Rolls-Royce Ghost3D printing-Additive manufacturing parts.

BMW Group for Rolls Royce3D printings component. ©BMW

These components are located in the body and passenger compartment of the vehicle and are powerful and robust.BMW Group is already in its“Additive Manufacturing Park” in Munich”Commissioned the component additive manufacturing process for mass production of automobiles. There, plastic parts were also manufactured using HP’s Multi Jet Fusion process. At the BMW Group plant in Landshut, the selection laser is currently being used Melting process to manufacture metal components.

BMW Group provides Rolls-Royce3D printingproduct. ©BMW

In the Dingolfing (Dingolfing) BMW Group factory work network, there are more than 300 experienced employees who manufacture the various bodies of Rolls-Royce cars, including the bodies of the new Rolls-Royce Ghost, and produce them for the BMW Z8 Body.

Use generative design for component development

Even in the early stages of the development of the new Rolls-Royce Ghost, engineers, manufacturing and materials experts analyzed hundreds of components and checked the use of3D printing-The feasibility of additive manufacturing process manufacturing. The focus here is how to achieve the advantages of weight and geometry and how to combine economic benefits compared with traditional methods.When selecting components suitable for additive manufacturing technology, the experts defined3D printingThe standards and requirements of the components, through the artificial intelligence system, the system enables the BMW Group to identify potential passable vehicles in the future faster and earlier3D printingTo mass-produced components.

BMW Group accelerates product iteration through generative design. BMW

By using generative design and computer algorithms to design parts, complex shapes can be created in a short period of time, which was almost impossible for engineers and designers to rely on manual work in the past. Generative design provides a way of human-computer interaction. Experts and computers design components together in order to obtain the most optimized design results.Generative design makes many potential applications a reality, and3D printingThe technology is particularly suitable for manufacturing these complex designs, which could not be produced by conventional traditional manufacturing processes before.

Use generative design to develop products. ©BMW

The BMW Group has created topology-optimized components for the Rolls-Royce Ghost. The weight of these components is on average nearly 50% less than that of traditional components. It can also make full use of the available space in the vehicle. A typical example is the bracket of the tailgate damper. .

The new Rolls-Royce Ghost model. ©BMW

BMW Munich Additive Manufacturing Park

Since June 2020, BMW has invested 15 million euros (over 100 million yuan) in Munich3D printingThe factory was officially launched, which established the BMW Group’s leading position in additive manufacturing technology in the automotive industry.With the support of Germany’s landmark IDAM program, BMW Munich’s3D printingThe factory has also built a modular and almost fully automated3D printing-Additive manufacturing production line.The additive manufacturing production line covers from digital design to parts3D printingThe whole process from manufacturing to post-processing. Due to the modular structure of the production line, it can be upgraded when necessary, and each module can be adapted to different production requirements. In addition, the process steps can be flexibly controlled. By comprehensively considering the requirements for integration into the automobile production line, the project partners plan to reduce the manual part of the process chain from the current approximately 35% to less than 5%. at the same time,3D printingThe unit cost of metal parts should be halved.

IDAM plan passed annually3D printingThe total output of manufactured parts is at least 50,000 series parts, thus enabling the BMW Group to help strengthen Germany’s3D printingThe role of pioneer. Partners in the IDAM program include Fraunhofer and Aachen University of Technology (ACAMR&D team members), other partners include Aconity Germany, GKN powder metallurgy, etc.

The president of ACAM explained how ACAM navigates complex additive manufacturing. Professor Schleifenbaum (also the dean of the DAP Academy andFraunhofer ILTLaser Material Processing Leader of the Laser Research Institute) and Dr. Arntz (alsoFraunhofer IPTManufacturing Process Leader of Manufacturing Research Institute)
DAP Academy and Fraunhofer areBMW GroupInitiatedIDAMThe core R&D member of the project. ACAM Aachen Additive Manufacturing Center

The BMW Group currently has 80 employees working in the Munich Additive Manufacturing Park, about 50 industrial metals and plastics3D printingThe equipment has been put into operation.In addition, BMW has also put into use more than 50 industrial3D printingsystem. According to the market understanding of 3D Science Valley,SLM SolutionsReleased the latest SLM® equipped with 12 1 kW lasers and a 600x600x600 mm molding chamber3D printingequipment-NXG XII 600, BMW Group is the first batch of delivery users of this equipment.

(Editor in charge: admin)