Base Materials Launches Large-Format 3D Printing Service to Replace Traditional Tooling Methods

[Industry Valley]

At a Glance​

• ProXtrude is a custom-formulated paste that offers structural durability, thermal stability, and dimensional precision.
• This process reduces material waste by 58% and shortens production times by 70%.
• A robotic cell measuring 6m x 2m x 2.5m produces large-format tools and prototypes.

# Base Materials has launched its large-format 3D printing service to offer manufacturers a faster and smarter alternative to traditional molding methods. This method involves a CNC-machined molding board. This process enables the production of complex, single-piece models with no visible bond lines. This allows for a reduction in material waste by up to 58% while shortening production times by up to 70% in internal trials. By eliminating the need for molds, casting, or bonding, and requiring only light finishing, the service significantly speeds up delivery times and helps reduce both consumable and material waste.

At the heart of the new service is ProXtrude, a newly custom-formulated, printable paste system that offers structural durability, thermal stability, and dimensional precision. Printed layer by layer using advanced robotic technologies, the service produces large-format, near-net-shape stock models in a dedicated robotic cell with a print area of 6m x 2m x 2.5m.

High-performance ProXtrude​

Located at Base Materials' facility in Birmingham, UK, each part is manufactured to stringent specifications, supporting even the most complex geometries, including hollow structures, thin-walled forms, and intricate overhangs. ProXtrude's high-performance characteristics result in stock models that offer advanced structural integrity and a refined surface finish, requiring only 10mm of CNC machining to meet final tolerance and aesthetic standards. This final step can then be completed by the customer or their preferred machining partner.

The system allows customers to take their designs to the next level. John Miller, Managing Director of Base Materials, said, "This investment is a significant milestone for Base Materials. Our large-format 3D printing service combines material innovation with digital manufacturing to deliver faster, cleaner, and more efficient tooling solutions." He added, "With our ability to print complex, full-scale models in a single piece — and doing so using our new, high-performance printable paste system, ProXtrude — we are helping our customers achieve new levels of design freedom and speed."

Pushing the boundaries​