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Bionic Production AG
Vor dem Neuen Tore 18
21339 Lüneburg

T.  +49 4131 230 0 230


Testing the world’s first 3D printed Bugatti brake caliper

The world’s largest 3D printed titanium pressure functional component ever produced on one of the most powerful brake test benches on the market! This is what it looks like when Bugatti prepares its first printed titanium brake caliper for series production.

Here can you find the video.

Be curious, the history of the brake caliper continues together with us.

Bionic Production at Formnext 2018

Four exciting days with interesting discussions and many new impressions are behind of us. We would like to thank you for visiting us at our booth. You were an important part of our trade fair success.

We are excited for the future cooperation and hope to welcome you again at Formnext 2019.


Bionic Production at the Aircraft Interiors Expo 2018

At the Aircraft Interiors Expo, Bionic Production AG demonstrated its capabilities in the field of 3d printing in aircraft interiors. As airlines in the premium segment are subject to great competitive pressure, they regularly need to revise their cabins in business and first class. With panels, which are created in 3d printing, the company shows how airlines can quickly and conveniently modernize the visual impression of their cabins without having to install completely new seats. On the AIX, the bionic production showed a seat with a panel with Bionic structures (see pictures below) to demonstrate that the design is limited in 3d printing. Since the panels do not need to be screwed, the replacement can even be made in the context of minor changes.

We thank you for your visit and we are looking forward to the Aircraft Interiors Expo 2019.


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Individual design DNA in every piece

Stand inkl. Sitz klein

Bionic Production AG and HOSA Aircraftcompletions GmbH invite you to discover various innovation to upgrade your aircraft seat. Let’s get inspired by light, heat, technical features and bionic design.

Come and visit us on our community booth:

Booth 6B 70/B

Aircraft Interiors Expo

10.-12. April 2018

Hamburg Fair, Germany

New Company Flyer


Bionic Production AG with „Bionic Smart Factory“ in Lüneburg: Innovation and Manufacturing at the New 3D-Printing Campus – as of 2018

Hamburg – November 2, 2017 – Bionic Production AG will move to a new location at the former Leuphana Campus Volgershall in Lüneburg early 2018. The company already presented its plans for „Bionic Smart Factory“ (BSF), a new manufacturing concept for complex 3D-printing, at the end of September. The major purpose of BSF is the economical production and design of components inspired by nature.


„Additive manufacturing methods gain importance in the industry, as new and more individualized products have the be produced more efficiently, with less material and in even lesser time. Additive manufacturing, digital business models, and Industry 4.0 offer additional potential to save costs,” said Wolfgang Bülow, CEO at Bionic Production AG. „With the Bionic Smart Factory we have created a factory structure that enables design inspired by nature and hence, offers tremendous cost savings. As a combination of additive manufacturing, bionic optimization, and digitalization along the process chain our factory enables new approaches for an economical production of individualized products.“


Bionic Smart Factory is a highly efficient production site for digital production and manufacturing, equipped with 3D printers for various materials and systems for post production steps. At its final stage of expansion the BSF will have around 20 3D-printers at its site in Lüneburg. The facility will not only be a production site, integrating additive manufacturing into the entire development, manufacturing and logistics chains, it will also be the base for innovative research and development projects, which will be conducted jointly with Laser Zentrum Nord GmbH.


Designed as a Campus, BSF offers future engineers the opportunity to work on and research innovative concepts jointly with developers and researchers. Being also a research center Bionic Smart Factory is open to cooperations. Fraunhofer Gesellschaft, being the first of many renowned organizations, has already confirmed their participation in the project. The 3D-Campus also welcomes innovative start-ups that focus on 3D-printing and the development of the technology, to establish their offices at the BSF.


By offering new professional perspectives to highly qualified engineers in the Lüneburg region, this so far first non-university research facility will strengthen the location and foster the economical development of the region. Initially, about 30 staff members will start working at the 3D-Campus as of the beginning of next year. For the future the company plans an extension of the facility to up to 100 employees.


Media Contact:                                                      Company Contact Bionic Production:
Evelyn Gebhardt                                                         Klaus Müller
Blue Gecko Marketing GmbH                                   Bionic Production AG
+49 6421 9684351                                                     +49 (0)40 48 40 10 526              

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BPG Company Flyer 2017 english

FORMNEXT 2017 – NOV 14th – 17th, 2017

14.-17. November 2017, Formnext opened its doors in Frankfurt and more than 20.000 trade visitors came to get an overview of Additive Manufacturing and the next generation of intelligent industrial production.


Some facts at a glance:


21.492 visitors, 54% from Germany and 46% from foreign countries

470 exhibitors

28.129 m² exhibition area

1.028 conference participants


We have enlarged our booth with the Laser Zentrum Nord together and presented more from the world of industrial 3D printing to our visitors. Above all, getting additive manufacturing in the automotive industry and ready for serial production was the most discussed topic during the show.

Many thanks for the numerous visits and the interesting conversations on our booth. We are happy over a very positive trade fair balance and looking forward to further exciting developments.


Certification Bionic Production AG

Customer satisfaction, process efficiency and the ability to react quick and flexible to market requirements are among the most important success factors in global competition.

We have been certified according to DIN EN ISO 9001 : 2015 since 2016 in order to fulfill the complex requirements for all processes as well as sustainably implement them.

In September 2017 we passed the annual monitoring audit and started the certification project according to EN 9100 for the new location in Luneburg. Find in us your competent and efficient partner!


Bionic design and advanced fabrication methods are the future of additive manufacturing Opinion: Paris 2017 And The Future Of Additive Manufacturing

Bionic design and advanced fabrication methods are the future of additive manufacturing

Designed with Nature

Four years ago, I had an epiphany at the 2013 Paris Air Show that additive manufacturing (AM) would disrupt the aerospace industry (AW&ST July 29, 2013, p. 10). At this year’s show at Le Bourget, it was clear that AM developments are already doing so.

General Electric, a leader in the field, last year purchased key European metal AM equipment suppliers Arcam and Concept Laser and this year stood up GE Additive, a new business focused on third-party equipment and services that it hopes will become its ninth major business unit. To demonstrate its independence, GE Additive had its own chalet in Paris. GE Aviation’s facility in Auburn, Alabama, now has 28 machines working around the clock to 3D-print its famous Leap fuel nozzles, with much more to come. An astounding 35% of its new Advanced Turboprop Engine for the Cessna Denali will be 3D-printed. Moreover, last month GE announced it is developing the world’s largest laser-powered 3D printer capable of handling parts within a 1-m2 (10.8-ft.2) envelope—ideal for large-engine structural parts.

Germany, meanwhile, boasts several well-organized AM clusters with active involvement from industry, government and academia. Why? According to Klaus Mueller, an executive with Bionic Production GmbH, “Germany leads because of our two-tier education system, which produces motivated engineers and highly skilled, self-thinking technicians.” German suppliers—including EOS, SLM Solutions, Trumpf and Concept Laser—control approximately 70% of the metal AM equipment market. And local aerospace manufacturers such as Airbus, MTU and Liebherr are aggressively pursuing the technology. New AM developments from all of these companies were on display in Paris. AM is now a mainstay with German medical equipment suppliers and is gaining momentum in the country’s large automotive sector.

While the early focus of AM was on powder-bed processes and small, complex and static parts, the technique has moved into large structural parts. The motivation is to attack large “buy-to-fly” ratios—often in the double digits—for parts made from expensive materials like titanium. A 20-lb. finished part, for example, might require 200-300 lb. of titanium, which creates $4,000 or more of scrap titanium per part

Picture: Concept Laser

Norsk Titanium developed a process in which wire is melted in a cloud of argon gas and rapidly built up in layers to a near-net-shape part that requires very little machine finishing, resulting in overall savings of up to 30% due to decreased waste and energy input. Norsk just qualified its first part for the Boeing 787 and has dozens more in development. The company is nearing completion of a large AM facility in Plattsburgh, New York, to complement its facilities in Norway.

Another recent development is the emergence of “bionic design”—using designs found in nature. Bird bones and lily pads, for example, have impressive strength-to-weight ratios and cannot be made by traditional subtractive manufacturing techniques. Airbus thinks bionic design could someday reduce aerostructure weight 20-30% or more. It has evaluated applying bionic design to thousands of parts and printed more than 100 demonstrators.

The additive-bionic combination, which was not on the radar at Paris in 2013, is analogous to the introduction of composites four decades ago. Early composite aerostructure designs, dubbed “black aluminum,” looked like metallic aircraft. It took several decades for designs to catch up to the unique properties of composites. “The mental mindset of engineers is one of the biggest obstacles for AM—particularly with bionic design taking hold,” says Mueller. “OEMs need to educate their engineers now if they plan to use bionics—especially if they are going to compete for future programs like the [Boeing] 797 in the next decade.”

AM economics are moving in the right direction. Titanium powder was more than $500/lb. four years ago; it is now 60-80% cheaper, as volumes increase. Processing rates are also increasing: AM fabrication machines featured one laser several years ago; next-generation machines with six lasers are on the horizon.

Despite all the good news, economics and regulation remain major barriers to more widespread AM adoption. Recertifying parts for existing aircraft is particularly challenging, which is why clean-sheet aircraft such as the much-anticipated 797 are so important. Its likely 2025-26 service-entry date will provide a window for suppliers to unveil new AM-empowered designs. Suppliers that ignore this wave do so at their peril.

The progress of additive manufacturing since Paris 2013 is impressive. As Mueller reminds us, “For 3,000 years, we have gained trust in molded and casted parts. We are 25 years into additive manufacturing, and just five years into taking it seriously.”

Contributing columnist Kevin Michaels is president of AeroDynamic Advisory in Ann Arbor, Michigan.

The views expressed are not necessarily those of Aviation Week.