BMW's 2027 Car Will Use 3D-Printed Metal Parts Made With WAAM

BMW is moving a 3D-printed metal car part from test track to showroom. The company confirmed that series production using wire arc additive manufacturing will start in 2027, and a new vehicle will debut with the first WAAM-produced structural component.

Timo Göbel, Head of Additive Manufacturing at BMW Group, said the specific part is still in final qualification. He could not disclose which model will receive it, but he confirmed the component is currently undergoing testing ahead of the vehicle's launch next year.

BMW has been exploring WAAM since 2015 and began building test components with an MX3D production cell in 2021. The process uses a welding wire fed through an arc to deposit metal layer by layer, making it well suited for large structural aluminium parts. Göbel noted that WAAM components are 30% to 40% lighter than standard die-cast aluminium parts while also costing less to produce.

"WAAM offers particular advantages for large metal components and high deposition rates over laser powder bed fusion, which is too slow and too expensive if you have such a big part," Göbel explained. "So, if the environment is good enough and the demand on the part is suitable, you are much faster with WAAM."

Since 2020, BMW's Additive Manufacturing Campus has produced more than 1.6 million 3D-printed parts, with an additional 100,000 coming from other vehicle plants each year. The technology currently supports development and validation of Neue Klasse vehicles and next-generation electric drive units.

WAAM is part of BMW's broader push to invest in larger build volumes and digitally connected process chains. The company sees growing opportunities for functional components that are stronger, more flexible to produce, and faster to manufacture than traditional tooled parts.