The BMW Group is increasingly using recycled materials from 3D printing waste to manufacture new components for production tools and devices across its global operations. Waste powder and used printed parts, once discarded, are now repurposed into filament and granulate for additive manufacturing.
Since 2018, the company has developed a closed-loop recycling system. Waste powder and shredded components are transformed into filament spools for Fused Filament Fabrication (FFF) and granulate for Fused Granulate Fabrication (FGF), enabling the production of large tools. These materials are primarily processed at the Additive Manufacturing Campus in Oberschleißheim and distributed across BMW’s global production network.
Paul Victor Osswald, Project Manager for Predevelopment Non-Metals, who has led the initiative since its inception, said: “The use of waste powder and discarded 3D printing components is a key element of a functional and efficient circular economy.”
What began with the “bottleUP” pilot project in 2018—recycling PET bottles for 3D printing—evolved into the regular use of industrial waste by 2019. By 2021, the team had begun producing holders and auxiliary production tools using its own recycled filament. The Oberschleißheim campus now consolidates production, research, and training in additive manufacturing, recycling up to 12 tonnes of material annually.
The Additive Manufacturing Campus also provides other BMW plants with a comprehensive toolkit—comprising recycled filament, printer specifications, and optimised parameters—enabling efficient local adoption of the technology. Training and knowledge-sharing efforts have helped build a collaborative network across BMW production sites, with the upcoming Debrecen plant in Hungary expected to benefit from these developments.
Currently, all BMW Group production sites are equipped with 3D printers, producing hundreds of thousands of components annually. Applications range from ergonomic tools and safety solutions to fitting aids, protective equipment, and specialised assembly tools.
Examples include a 3D-printed component in Plant Munich used during the marriage of chassis and body, which helps position the steering rod safely, and custom pedestals at the Berlin Motorrad plant that secure motorcycle trim panels during decor application. At Dingolfing, employees designed magnetic holders via 3D printing to prevent screws from being lost during assembly.
The integration of 3D printing continues to drive flexibility and efficiency in BMW’s manufacturing processes, supporting faster iteration and reducing potential production delays.
