BMW Leverages 3D Printing for Improved Robotic Gripper Design

Additive manufacturing has become a fully-fledged production process for the BMW Group. For over 30 years now, the automaker has relied on 3D printing for the manufacture of automotive parts, tools, work aids, and training. The “Additive Manufacturing Campus” in Oberschleißheim plays a central role in this development. Last year, a total of over 300,000 parts were printed here, using a variety of processes. More recently, at the same center, the automaker unveiled 3D-printed XXL grippers. They have been installed on a press for the production of all the German brand’s carbon-fiber-reinforced polymer (CFRP) roofs.

This robotic gripper, weighing approximately 120 kilograms and requiring 22 hours for printing, showcases the efficiency of additive manufacturing. By leveraging this process, the final product achieves a 20% reduction in weight, significantly enhancing operational efficiency. The manufacturing process combines two techniques: SLS for crafting vacuum and needle grippers crucial for lifting CFRP, and Large Scale Printing (LSP) for producing the expansive roof shell and load-bearing structure. Notably, LSP utilizes recycled plastic injection pellets, rendering it exceptionally conducive to economically and sustainably manufacturing large components. As a result, the process yields a notable 60% decrease in CO2 emissions during the production of the grippers.

Example of a 3D-printed gripper at the Regensburg plant

Jens Ertel, Head of BMW Additive Manufacturing, explained, “The increasing use of additive manufacturing in the BMW Group production system has many benefits. For example, we are able to quickly, economically, and flexibly produce our own production aids and handling robots, which we can individually adapt to specific requirements at any time, as well as being able to optimise their weight. Less weight allows higher speeds on the production line, shorter cycle times and reduced costs. Plus, smaller robots can be used in the medium term, which also cuts CO2 emissions and costs.”