Bentley Motors, based in Crewe, is celebrating 25 years of integrating additive manufacturing (AM) into its operations. The company has made significant investments in its facilities and technologies in recent years. What started as an effort to incorporate 3D printing into the development of Bentley’s first-generation Continental GT has grown into a cutting-edge facility with 13 3D printers.
Initially located in the oldest building on Bentley’s Pyms Lane site, A1, the 3D printing facility has since been moved to the new Engineering Technical Centre. This move highlights Bentley’s commitment to staying at the forefront of innovation in advanced manufacturing techniques and product development.
The AM facility at Bentley uses a range of advanced technologies that support the full development and production process across various business areas. One notable example of its capabilities is the use of 3D-printed solid rose gold in the interior of a bespoke model, the “Black Rose.” This luxury car, one of only three right-hand-drive Baturs, features 210 grams of hallmarked 18-carat rose gold at key touchpoints for the driver.
Dr. Matthias Rabe, Bentley’s Member of the Board for Research & Development, commented on the importance of additive manufacturing in their development process. “AM plays a crucial role in product development,” he said. “Our expertise in this field has grown significantly, enabling us to rapidly produce and refine components. This will continue to enhance how we develop our cars, especially as we electrify our range and create the next generation of extraordinary vehicles.”
Advanced Technologies at Work
Bentley’s AM facility is designed to select the best materials and processes for each application. It produces large functional components using Fused Deposition Modelling (FDM) and creates aerodynamic test models using Multi-Jet Fusion (MJF) technologies.
One of the team’s notable achievements is the 3D printing of a W12 engine block, scaled down to just 5mm wide. Despite its small size, the model retains all the intricate details of the full-size engine, thanks to Lithography-based Metal Manufacturing (LMM) technology. This pioneering 3D metal printing process ensures unmatched precision and supports rapid prototyping, bespoke tooling solutions, and more sustainable product development by reducing material waste.
Supporting the Community and Sustainability Efforts
Bentley’s commitment to additive manufacturing extends beyond product development. During the Covid-19 pandemic, the AM team produced over 20,000 pieces of personal protective equipment (PPE) for NHS staff and local care homes. Additionally, the team has been exploring sustainable practices, such as reusing excess polymer powder from the MJF process to create filament for FDM printing. This recycling initiative reduces waste and accounts for around 60% of the material output at the AM facility.
As Bentley celebrates 25 years of success in additive manufacturing, the company continues to push the boundaries of innovation, shaping the future of luxury automotive design and manufacturing.
