The BMW Group is significantly expanding its use of 3D-printed, customised robot grippers across its production network as these innovations are fast, economical, and versatile, enhancing manufacturing processes and efficiency.
At BMW Group Plant Landshut a new bionic gripper has been introduced providing substantial weight savings. This tool is designed to handle CFRP roofs reducing its weight by 25 percent compared to its predecessor. The gripper combines elements made using selective laser sintering (SLS) and large-scale printing (LSP), utilising recycled materials and reducing CO2 emissions by approximately 60 percent compared to traditional methods.
The BMW Group has also implemented an innovative bionic gripper at its Munich plant capable of handling entire floor assemblies for the BMW i4. This new gripper, produced using a sand casting mould filled with liquid aluminium, is 30 percent lighter than the conventional model. The reduced weight allows for the use of smaller, lighter robots, which require less energy and contribute to lower CO2 emissions. Markus Lehmann, Head of Plant Engineering and Robotics at BMW Group Plant Munich, mentions 'When handling the full BMW i4 floor assembly, this allowed us to reduce the weight of the complete gripper by 30 percent – 50 kg – and thus to extend the service life of our facilities.'
BMW's dedication to additive manufacturing extends beyond robot grippers. The company's Additive Manufacturing Campus in Oberschleißheim serves as a central hub for research, production, and training in 3D printing. In 2023 alone, the campus produced over 300,000 parts, with an additional 100,000 parts produced across BMW's global production network, including plants in Spartanburg and various sites in Asia.
Additionally, BMW has been using sand-based 3D printing for many years to create moulds for prototype casts and large-scale production components, particularly aluminium cylinder heads. This technology allows for the creation of complex structures by applying sand in thin layers and binding them together, which are then filled with liquefied aluminium.
The Lightweight Construction and Technology Centre in Landshut has been using 3D printing to manufacture large robot grippers for CFRP roofs for several years. The gripper, weighing around 120 kilograms, can be produced in just 22 hours and significantly reduces cycle times in the production process.
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