Foundries today face increasing pressure to produce complex, high quality tooling efficiently, with minimal waste and maximum design freedom. Base Materials’ large format 3D printing service, powered by their propietary ProXtrude® printable paste system, helps foundries meet these challenges by offering a faster, more precise and lower waste alternative to traditional tooling methods.
High performance tooling with ProXtrude®
ProXtrude® is a specially formulated 900kg/m3 density printable paste system engineered for structural strength, thermal stability and dimensional precision. Using advanced robotics at Base Materials’ Birmingham (UK) facility, parts are printed layer by layer in a 6m x 2m x 2.5m print bay, producing single piece, near-net-shape models with no visible bond lines.
Only minimal CNC machining, typically 10mm, is needed to achieve final tolerances and surface finish. This reduces post production time and labour, enabling foundries to accelerate lead times by up to seventy per cent compared with conventional methods.*
Optimised for foundry applications
The service suits a wide range of tooling needs:
· Patterns: Large, hollow or complex patterns that would otherwise require blocking up, casting or assembly.
· Core boxes: Intricate, lightweight single piece components for improved accuracy and repeatability.
· Prototype development: Fast tracked trial castings, design validation and short run production.
· Large single piece tools: Eliminating bonding or assembly improves structural integrity and reduces errors.
By removing time consuming steps like blocking up bonding and lengthy CNC machining to shape, 3D printing simplifies workflows, reduces material waste and enables faster production.
Sustainability benefits
Traditional methods often generate significant offcuts and scrap. 3D printing constructs each model layer by layer to a near-net-shape, dramatically reducing material waste. Internal testing shows material savings of up to 58 per cent compared with conventional methods*, supporting ESG goals without compromising performance or design freedom.
Collaborative, customer focused service
Base Materials works directly from a customer’s CAD designs, providing expert consultation to ensure tooling is produced efficiently and reliably. The ProXtrude® printable paste system is also available for companies with in-house 3D printing capabilities, offering further flexibility for bespoke projects.
Unlocking design freedom
With large format capability, single piece construction and suitability for complex shapes, including overhangs and thin-walled components, this service allows foundries to realise intricate forms and large structures without compromising durability or detail.
For faster production, improved design flexibility, and reduced material waste, Base Materials’ large format 3D printing service and ProXtrude® system provide a next generation solution.
“By combining material innovation with advanced digital manufacturing, we’re able to offer foundries a faster, cleaner and more efficient approach to tooling production. Our large format 3D printing capability and ProXtrude® printable paste system allow complex tooling to be produced as single piece structures, reducing waste, shortening lead times and giving customers far greater design freedom,” said John Miller, managing director, Base Materials.
To learn more, visit: https://base-materials.com/solutions/3d-printing-service/
*Internal testing data, side by side comparison, October 2025.