OPERATIONS analysis of the previous design. The result was a bionic gripper modelled on the load-bearing logic of natural forms such as bone or branching systems.
The new gripper is 25 % lighter than its predecessor. This allows for the entire CFRP roof manufacturing process for the BMW M3 to be carried out by a single robot, where previously three were needed. Less robots in the cell means fewer systems to maintain, fewer potential failure points and lower energy consumption.
Software automation Designing bionic structures requires specialist computational tools. BMW uses software called Synera to perform topological optimisation calculations, removing material from areas of low stress and retaining it where loads are highest.
These designs can be sent directly to a 3D printer without further modification. At the Additive Manufacturing Campus, standardised workflows now automate lots of the calculation and design process, reducing the time between identifying a maintenance need and producing a finished replacement part.
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