Bentley Motors is celebrating 25 years of Additive Manufacturing (AM), marking a milestone in innovation and engineering excellence at its global headquarters in Crewe. The luxury automaker has significantly expanded its 3D printing capabilities to support the development of its first fully electric vehicle (BEV), set to debut in 2026 as the world’s first Luxury Urban SUV.

Expanding 3D Printing Capabilities at Bentley

Since introducing 3D printing during the early development of the original Continental GT, Bentley has evolved its AM operations into a state-of-the-art facility. Now located within the new Engineering Technical Centre, the facility houses 13 advanced machines utilizing six cutting-edge AM technologies.

Originally situated in Building A1—the oldest structure at the Pyms Lane site, now being transformed into Bentley’s dedicated BEV production line—the move underscores Bentley’s transition toward an electrified and sustainable future.

Key Achievements Over 25 Years:

• Over 125,000 3D printed components produced in-house
• Expanded AM applications across design, prototyping, and production
• Integration of sustainable printing processes using recycled materials

AM Technology Enhancing Product Development

Bentley’s AM facility supports a broad spectrum of design and manufacturing functions, enabling rapid prototyping, low-volume production, and bespoke tooling. Advanced techniques such as Fused Deposition Modelling (FDM) and Multi-Jet Fusion (MJF) allow for both large-scale components and aerodynamic test models.

One standout example includes a 3D printed W12 engine block scaled to just 5 mm, made possible using Lithography-based Metal Manufacturing (LMM). This method ensures ultra-high precision for even the most intricate metal parts.

Luxury Meets Innovation: The Black Rose Batur

In a world-first application, Bentley incorporated 3D printed solid rose gold into “The Black Rose” – a bespoke commission of the rare right-hand-drive Batur coupe. A total of 210 grams of hallmarked 18-karat rose gold were added to the vehicle’s interior, delivering tactile luxury through precision-crafted driver touchpoints.

Driving Sustainability and Community Impact

Beyond vehicle production, Bentley’s AM operations extend to community support and environmental responsibility:

• Produced over 20,000 PPE items during the COVID-19 pandemic for NHS staff and local care homes
• Reuses excess polymer powder from MJF processes in FDM printing
• Approximately 60% of AM material output is repurposed, reducing waste and enhancing sustainability

Expert Insight on AM’s Role in Bentley’s Future

Dr. Matthias Rabe, Bentley’s Member of the Board for Research and Development, commented:

“Additive manufacturing continues to play a vital role in our product development. Our capability and expertise in this field have grown tremendously. As we electrify our model range, AM provides the flexibility and speed we need to shape the next generation of extraordinary Bentley vehicles.”