Base Materials launches an innovative large-format 3D printing service to provide manufacturers with a faster, smarter alternative to traditional tooling methods, where the tooling board is CNC-machined. The process enables the production of complex, single-piece models with no visible bond lines, while cutting material waste by up to 58% and reducing production timelines by as much as 70% in internal trials. By eliminating the need for moulds, casting or bonding and requiring only light post-processing, the service significantly accelerates lead times and helps reduce both consumable waste and material waste.
At the heart of the new service is ProXtrude®, a specially formulated, novel, printable paste system that offers structural strength, thermal stability and dimensional precision. Printed layer-by-layer using advanced robotics, the service produces large-format, near-net-shape stock models in a dedicated robotics cell with a 6m x 2m x 2.5m print bay.
Located at Base Materials’ facility in Birmingham, UK, each part is manufactured to tight specifications, supporting even the most complex geometries – including hollow structures, thin-walled forms and intricate overhangs. The high-performance characteristics of ProXtrude® result in stock models that exhibit enhanced structural integrity and a refined surface finish, requiring just 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.
John Miller, Managing Director of Base Materials, commented: “This investment marks 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. With the ability to print complex, full-scale models in a single piece – and do so using our new ProXtrude®, high-performance printable paste system – we’re helping our customers embrace new levels of design freedom and speed.
“We see this as a pivotal innovation for industries where the demands for lightweighting, rapid prototyping and reduced material waste to support ESG commitments are growing every year. By offering precision additive manufacturing in addition to traditional tooling methods, we're not only pushing the boundaries of what’s possible in tooling design but also supporting manufacturers in their innovation journey.”
The large-format 3D print service is ideal for industries where large-format tooling, prototypes, lightweight or hollow components, and intricate designs are key. The process is fully managed by Base Materials’ technical team, providing expert support and consultation at every stage.
Base Materials ProXtrude® printable paste system is also available as a stand-alone product for companies with their own in-house 3D printing capabilities.
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