Using our specially engineered ProXtrude® printable paste system, we produce single-piece, near-net-shape stock models with no visible bond lines and up to 58 % less material waste*.
Models are printed layer-by-layer using advanced robotics in our dedicated robotics cells with a 6 m x 2 m x 2.5 m print bay, at our facility in Birmingham, UK.
The high-performance characteristics of ProXtrude® result in stock models that exhibit enhanced structural integrity and a refined surface finish, requiring just 10 mm of CNC machining to meet final tolerance and aesthetic standards – saving you both time and resources.
This technology offers a more efficient, lower-waste alternative to traditional blocking-up methods, where the tooling board is blocked up and CNC-machined to the desired shape.
*Compared to traditional methods. Based on internal testing, October 2025.
Our service
Working directly from your CAD designs, we print large-scale stock models using our ProXtrude® paste system - specifically formulated for stability, strength and precision. 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.
Our ProXtrude® printable paste system is also available as a stand-alone product for companies with their own in-house 3D printing capabilities.
DRIVING SUSTAINABILITY GOALS
One of the key advantages of our large-format 3D printing approach is its impact on sustainability compared to traditional methods. Unlike traditional tooling boards which are blocked up and CNC machined, which can generate substantial offcuts and waste material, 3D printing constructs each stock model with precision—layer by layer—dramatically reducing waste. Our internal testing has shown 3Dprinting can reduce material waste by up to 58%*.
By leveraging this advanced technology, we can help customers achieve their environmental, social, and governance (ESG) objectives while delivering the creative freedom and efficiency today’s markets demand.
*Compared to traditional methods. Based on internal testing, October 2025.
Talk to us about your requirements for expert advice and reccomendations
key features and benefits
- Large-scale capability
- Single-piece construction – no bonding, moulding or casting, eliminating visible bond lines and improving the appearance of your tooling
- Supports complex designs – ideal for overhangs, hollow parts and intricate geometries
- Engineered for performance - our ProXtrude® paste system is developed for strength, stability and precision
- Accelerated lead times – reduce production timelines by up to 70% compared to traditional tooling methods*
- Reduced waste material – up to 58% less material waste*
- Minimal finishing required - just 10mm of material requires CNC machining, reducing time and labour
- UK-based service – expert support throughout the process and local delivery
- ProXtrude® printable paste system available as a stand-alone product
*Based on internal testing, October 2025.
APPLICATIONS
- Large-format tooling
- Lightweighting
- Prototypes
- Hollow, lightweight or thin-walled components
- Complex shapes and intricate overhangs
WHAT CAN BE PRODUCED WITH LARGE-FORMAT 3D PRINTING?
With its expansive print bay, our large-format 3D printing service is capable of delivering single-piece models for a wide range of demanding applications. The technology is ideally suited for manufacturing:
- Full-scale tooling
- Display and sculptural art pieces
- Bespoke prototypes
- Hollow, lightweight or thin-walled components
- Complex shapes and intricate overhangs
The service provides manufacturers and designers with the freedom to realise intricate forms and large structures, all without compromise on detail or durability.
EXPLORING ALTERNATIVE MANUFACTURING TECHNOLOGIES
While our large-format 3D printing service brings speed and design flexibility, we recognise that every project has its own unique requirements. If large-format 3D printing isn’t the ideal fit for your application, rest assured, there’s an array of alternative options available.