BMW Group is set to implement one of the largest 3D printed polymer components in a commercial vehicle with a new center console carrier scheduled for production in 2027. The component recently won the SPE Central Europe AutomotiveAward in June 2024, marking the first time a 3D printed part has received this recognition.
The new design consolidates what was previously a seven-part assembly into a single 3D printed component, measuring 300 × 300 × 1,000 mm and weighing approximately 4 kg. The console integrates two air ducts that traditionally required separate tooling-based molding processes, streamlining the manufacturing workflow.
Hans Weber Maschinenfabrik will supply the robotic 3D printing systems for BMW’s in-house production of these components. Each console requires about 3 hours and 40 minutes to print on Weber’s DXR platform MEX or LSP systems, using a single-screw Weber AE 20 extruder.
The project will utilize Akro-Plastic’s Akromid PA11 material, which contains 40% recycled carbon fiber and renewable raw materials. The new design achieves a 30% weight reduction compared to the conventional assembled version, contributing to improved vehicle efficiency.
BMW plans to produce approximately 18,000 center console carriers annually using this method. The combination of design optimization, material selection, and manufacturing approach results in a carbon reduction of about 70 kg per vehicle compared to traditional manufacturing methods.
Source: ptonline.com
