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The BMW Group has lengthy been a consumer and innovator in additive manufacturing (AM) expertise, relationship again practically 35 years. However, the auto large by no means fails to impress within the milestones it makes with the expertise, most lately within the realm of automation for 3D printing plastic, metallic, and sand components. Circa 2015, the corporate turned its consideration to wire arc additive manufacturing (WAAM), able to producing massive, metallic components shortly and effectively. Now, in keeping with the automaker, BMW is aiming to start testing WAAM components in automobiles beginning subsequent yr.
WAAM diverges from conventional strategies by using a wire—aluminum being the fabric of selection for car producers—melted through an arc to construct layers of welding seams, orchestrated by a software-controlled robotic. The expertise is ready to create hole buildings, yielding parts with an distinctive rigidity-to-weight ratio, surpassing the attributes of parts produced by standard die-casting strategies. Not solely does this lead to components which might be each lighter and sturdier, however it additionally options decreased vitality necessities and minimized materials waste.
BMW started to exploring WAAM in 2015 earlier than putting in a robotic cell in 2021. By 2022, the automobile firm had develop into a buyer of WAAM unique tools producer MX3D. Whereas powder mattress fusion—which BMW has now was an automatic course of—is right for smaller components, WAAM is healthier fitted to sections within the car physique, drive, and chassis. Because of this, the agency has 3D printed a suspension strut assist that’s being matched towards a die solid counterpart.
“On this early stage it’s already clear that the WAAM course of can lead to decrease emissions within the manufacturing course of. The decrease weight of the parts, their advantageous materials utilization ratio, and the choice to make use of renewable vitality implies that the parts may be produced extra effectively,” stated Jens Ertel, Head of BMW Additive Manufacturing.
A technical drawing of the WAAM suspension strut.
To create optimum components for implementation in automobiles, BMW has turned to generative design. Just like the ideas of bionic buildings, the preliminary step includes using solely the important materials wanted for the element’s topology. Within the subsequent fine-tuning part, further reinforcement is utilized selectively, solely in areas the place it’s required.
“It’s spectacular to see how WAAM expertise has developed from analysis to develop into a versatile device for not solely check parts but additionally collection manufacturing parts. Using generative design strategies allows us to make full use of design freedom and thus the potential of the expertise. That was unthinkable just some years in the past,” stated Karol Virsik, Head of BMW Group Automobile Analysis.
Simply as BMW tackled the ending wants for different 3D printing applied sciences, through government-backed consortia, the auto firm will possible have to do the identical for WAAM components. The parts bear a particular rippled floor as a result of broader welding seams, necessitating further ending for important areas.
WAAM expertise, Jens Ertel, Head of BMW Additive Manufacturing, Karol Virsik, Head of BMW Group Automobile Analysis.
Initially, the BMW Group intends to centralize the WAAM manufacturing of parts in on the Additive Manufacturing Campus in Oberschleißheim. Nonetheless, there are plans to broaden manufacturing to further places sooner or later and to allow suppliers to make the most of this expertise as effectively. Furthermore, the chance exists to combine this course of instantly into the meeting line, permitting for the creation of distinctive parts and the manufacturing of assorted components with out the necessity for brand spanking new instruments, merely by updating the software program. Moreover, the sustainability of the method might be enhanced additional by escalating the utilization of recycled metals. After finishing check bench evaluations, the preliminary car trials are scheduled to start in 2025.
All pictures courtesy of BMW.
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