Bentley marks 25 years of additive manufacturing excellence

Bentley celebrates 25 years of 3D printing at its Crewe HQ, advancing electric vehicle design and sustainability. Discover the impact of AM.

Bentley Motors is marking 25 years of additive manufacturing (AM) at its Crewe headquarters, a milestone that underscores not only the brand's technological evolution but also its dedication to innovation and sustainability in the age of electrification.

What began in 1999 with a single FDM machine has grown into a cutting-edge facility within the company’s new Engineering Technical Centre, housing 13 machines across six advanced 3D printing technologies. More than just an upgrade, this transformation aligns with Bentley’s strategic roadmap toward electrification, including the launch of its first fully electric vehicle — a luxury urban SUV scheduled for 2026. The EV will be built on the Volkswagen Group’s PPE platform and assembled at the historic A1 building, the original AM site.

Over a quarter century, Bentley’s AM division has produced more than 125,000 parts — ranging from large functional components to aerodynamic test models. One standout: a W12 engine block scaled down to just 5 mm and crafted with lithography-based metal manufacturing (LMM) for unmatched precision. On the customization front, Bentley made headlines with “The Black Rose” Batur, which includes up to 210 grams of 18-karat rose gold, 3D-printed for tactile interior elements.

The company has invested over £3 million to expand AM capacity, halving the cost of individual parts and accelerating time-to-market. Sustainability is central to this strategy: excess polymer powder is recycled into filament, and during the COVID-19 pandemic, the team produced over 20,000 items of PPE for NHS and care facilities — a tangible demonstration of technology’s broader impact.

As luxury carmakers embrace personalization, Bentley is leading the way in integrating AM not as an accessory but as a cornerstone of product design, efficiency, and environmental responsibility. While competitors like Rolls-Royce and Aston Martin also utilize AM in aerospace and engine component production, Bentley’s full-spectrum application of the technology positions it as a true pioneer in redefining automotive craftsmanship.

Source: bentleymedia.com