BMW boosts circular economy with large-scale recycled 3D printing

BMW uses waste powder and parts to produce recycled filament for 3D printing, expanding sustainable production and cutting costs globally.

The BMW Group is taking a bold step toward a circular manufacturing system by repurposing 3D printing waste into new functional components. Instead of discarding leftover powder and worn-out printed parts, the company now transforms them into valuable raw materials.

This recycled input is used to produce filament and granulate, which serve as the basis for various auxiliary tools and devices across BMW’s global production network. At the heart of the initiative is the Additive Manufacturing Campus in Oberschleissheim, where up to 12 tonnes of waste per year can be reprocessed. The site combines development, training, and industrial application under one roof.

More than just supplying material, the Campus supports production sites with a complete rollout package: recycled filament, optimized printing parameters, printer recommendations, and employee training. This ensures that plants can implement the process efficiently and achieve consistent, high-quality results.

The journey began in 2018 with the bottleUP project, turning PET bottles into printable material. By 2021, the team had successfully 3D-printed the first auxiliary devices using their own recycled filament. Today, every BMW production plant is equipped with 3D printers using this system.

Practical examples illustrate the impact: at BMW’s Munich plant, a 3D-printed component temporarily secures the steering rod during body-to-chassis assembly. In Berlin, custom pedestals aid the precise application of decals on motorcycle trim panels. At the Dingolfing plant, workers developed magnetic screw holders to improve assembly ergonomics.

3D printing dramatically accelerates production. Components that used to take weeks can now be delivered in hours or days, helping avoid costly delays. These capabilities are especially critical for BMW’s newest site in Debrecen, Hungary, which will enter virtual pilot operation in late 2024 ahead of Neue Klasse EV production in 2025. By simulating processes in advance, the plant can identify bottlenecks early and increase efficiency.

Economic benefits are equally clear: additive manufacturing and material recycling have led to production cost reductions of up to 50%. Since 2020, BMW has invested over €38 million into the Oberschleissheim campus to support these advancements.

The project is backed by strategic partnerships with technology firms including Carbon, Desktop Metal, and Xometry. In casting operations, BMW uses advanced binder-jet printers supplied by Laempe Mössner Sinto at its Landshut facility.

Although no official customer-facing spare parts printing program is in place yet, the growing scale — with over 400,000 printed parts produced annually — signals strong potential for expansion in the future.