Marking a major milestone in cutting-edge automotive design, Bentley Motors is celebrating 25 years of Additive Manufacturing (AM), more commonly known as 3D printing. Originating in the development phase of the first-generation Continental GT, Bentley’s AM journey has evolved into an advanced production capability at its Crewe headquarters.

A High-Tech Hub in Crewe

Housed within the new Engineering Technical Centre, the AM facility now comprises 13 machines employing six distinct technologies. This relocation from the historic A1 building—now the forthcoming assembly line for Bentley’s first fully electric vehicle—underscores the brand’s pivot towards sustainable luxury and BEV development.

Notably, AM is crucial in creating prototype components for Bentley’s inaugural Luxury Urban SUV, set to debut in 2026.

Breakthroughs in Luxury Craftsmanship

A hallmark achievement includes the industry-first integration of solid rose gold 3D-printed elements in The Black Rose—a bespoke Baturs model. Weighing up to 210 grams, these 18-karat rose gold touchpoints exemplify the blend of technology and artisanal elegance.

Technical Excellence in AM Technologies

Bentley’s AM capabilities span diverse processes:

• Fused Deposition Modelling (FDM): Producing large, functional components
• Multi-Jet Fusion (MJF): Crafting aerodynamic test models
• Lithography-based Metal Manufacturing (LMM): Delivering extreme precision, even rendering a W12 engine block in just 5 mm width with intricate accuracy

These technologies facilitate rapid prototyping, single-print parts, scale models, and sustainable tooling solutions, reducing material waste significantly.

The Bottom Line

Beyond the workshop, Bentley’s AM team contributed over 20,000 PPE items to the NHS during the pandemic. Sustainability efforts continue with the repurposing of polymer powder waste—60% of material output—into reusable FDM filaments.

“Additive manufacturing continues to play a vital role,” says Dr. Matthias Rabe, Bentley’s R&D Chief. As Bentley advances toward electrification, its 3D printing prowess remains a cornerstone of its innovative, sustainable luxury vision.