The BMW Group is taking a step toward a more sustainable production model by integrating recycled materials into its additive manufacturing workflows. By reusing plastic waste like used 3D printing powder and discarded parts, the company is 3D printing new components.
Turned into plastic filament and granulate, previously discarded waste powder and shredded components are used in Fused Filament Fabrication (FFF) and Fused Granulate Fabrication (FGF) processes to make tools and auxiliary production devices at the BMW Group’s Additive Manufacturing Campus in Oberschleißheim and across its global network.
“I’ve been involved with this project from the very beginning and I’m thrilled to see how far we’ve come, from our initial ideas and attempts at startup level to now being able to produce large quantities of highly robust components from recycled filament at any BMW Group production location,” Paul Victor Osswald, project manager for Predevelopment Non-Metals at BMW, said in a press release. “The use of waste powder and discarded 3D printing components is a key element of a functional and efficient circular economy.”
The initiative took off in 2018 as the “bottleUP” project, exploring how to recycle PET bottles into 3D printing materials. By 2021, Osswald’s team had printed the first tools using their own recycled filament. Today, up to 12 tonnes of waste powder can be repurposed annually.
The Additive Manufacturing Campus plays a pivotal role in deploying this solution across the entire company. Not only does the hub provide recycled filament, but also printer recommendations, validated settings, and on-site training. This approach has created a global network of BMW sites equipped with 3D printing capability, supporting faster turnaround and localized innovation.
Applications include a diverse range, from fitting aids to scratch protection to specialized tools and mounts. Some examples are a 3D-printed part stabilizing the steering rod during vehicle assembly at Plant Munich, or custom pedestals securing motorcycle trim panels during decor application in Berlin.
