3D printing with recycled material at BMW

The BMW Group is increasingly focusing on recycling in 3D printing: used powder and components from the additive manufacturing process are no longer disposed of but recycled. The material is processed into plastic wire (filament) or granulate and then used for new printing processes - for example to manufacture production aids and tools. The recycled filament is wound onto spools and used at the Additive Manufacturing Campus in Oberschleissheim and at other locations in the global BMW production network. In addition to filament for the Fused Filament Fabrication (FFF) process, the Campus also provides granulate for Fused Granulate Fabrication (FGF) technology - ideal for larger applications in the construction of auxiliary equipment. A closed material cycle that not only conserves resources, but also makes additive manufacturing even more sustainable.

"I have been involved in this project from the very beginning and am very pleased that we have now come so far from initial ideas and trials at start-up level that we are now able to manufacture highly resilient components with recycled filament in large quantities and at any desired BMW Group production site. It is an exciting task to be able to keep developing and testing new processes. The use of used powder and disused 3D printed components is an important building block for a functioning and efficient circular economy," says Paul Victor Osswald, Project Manager Advanced Development Plastics, who has been involved in the development since 2018.

First steps as early as 2018

The first foundations for today's 3D printing cycle at the BMW Group were laid back in 2018. As part of the BMW Start-up Accelerator, the BottleUp innovation project focused on obtaining printing material for 3D printing applications by recycling PET beverage bottles. One year later, the first industrial waste was recycled into filament on a pilot basis and in 2021, Paul Victor Osswald's team successfully printed the first holders and production aids from their own recycled filament.

The Additive Manufacturing Campus in Oberschleissheim, where the BMW Group has bundled production, research and training in the field of additive manufacturing under one roof, now supplies various locations in the BMW Group production network worldwide with printed components. Each year, up to 12 tons of used powder can be recycled into filament and granulate and can then be reused for the production of production aids in the plants and for pre-development projects at the Additive Manufacturing Campus. The use of these components reduces costs, increases process efficiency and product quality and improves the ergonomics of employees in the plants.

The BMW Group's Additive Manufacturing Campus is driving the spread of its own recycled filament and supporting other plants with expertise, printer recommendations and tried-and-tested parameters. Together with experienced locations, suitable 3D printers are tested and optimally adapted to the recycled material. This enables new plants to achieve high-quality printing results quickly and efficiently. The campus also offers comprehensive training courses - from basic knowledge to special training for use in the production environment. A growing network promotes cross-location exchange, from which the new 3D printing area at the Hungarian plant in Debrecen is already benefiting.