---
title: "BASF expands production capacity for X3D catalyst shaping"
url: https://www.voxelmatters.com/basf-expands-production-capacity-for-x3d-catalyst-shaping/
date: 2024-11-15
modified: 2024-11-15
lang: en
author: "Edward Wakefield"
description: "BASF, an industrial chemical company, is investing in additional production capacity, in Ludwigshafen, Germany, for its X3D catalyst shaping technology for 3D printing. The plant will produce catalysts on an..."
categories:
  - "Advanced Materials"
  - "Materials"
  - "Metal Additive Manufacturing"
  - "Metals"
  - "Precious Metals"
  - "Sustainability"
tags:
  - "future"
image: https://www.voxelmatters.com/wp-content/uploads/2024/11/X3D-N2O-640x360.jpeg
word_count: 344
---

# BASF expands production capacity for X3D catalyst shaping

[BASF, an industrial chemical company](https://www.voxelmatters.directory/company/basf-se/), is investing in additional production capacity, in Ludwigshafen, Germany, for [its X3D catalyst shaping technology](https://www.voxelmatters.com/basf-introduces-x3d-an-am-based-approach-to-catalyst-shaping/) for 3D printing. The plant will produce catalysts on an industrial scale and is expected to be operational in 2026. X3D technology produces catalysts with optimal shapes to maximize performance and efficiency while minimizing energy consumption.

Catalysts produced using this technology are not only mechanically robust but also feature an open structure, which significantly reduces pressure drop across reactors and increases surface area. These advancements translate into improved catalyst performance - helping customers to achieve greater efficiency in their plants. Benefits include increased reactor output, higher product quality, and lower energy consumption - contributing to customer’s green transformation goals.

X3D technology can be applied to a wide array of catalytic materials, including both precious and non-precious metal catalysts, as well as carriers. This flexibility allows BASF to customize catalysts according to specific customer requirements by fine-tuning parameters such as infill patterns, fiber diameters, and orientations.

![BASF expands production capacity for X3D catalyst shaping. The expanded plant is expected to be operational in 2026.](https://www.voxelmatters.com/wp-content/uploads/2024/11/BASF_CAT-006682_X3D_PressR.jpeg)

“[BASF remains committed](https://www.voxelmatters.com/basf-forward-ams-management-takes-over-all-of-basfs-am-activities/) to leading the charge in innovation within the chemical catalysts industry. X3D represents a step-change advancement in technology for catalyst production. We are proud to give our customers new opportunities to boost the performance of their production and at the same time reduce their carbon footprint,” said Detlef Ruff, Senior Vice President of process catalysts at BASF.

"[BASF has successfully](https://www.voxelmatters.com/basf-forward-am-grows-by-39-in-h1-2023/) operated commercial plants using X3D catalysts for several years, achieving remarkable results. This technology is poised to shape the future for both green and traditional value chains with unparalleled efficiency and improved speed-to-market,” said Jens Perregaard, Vice President of custom catalysts and innovation at BASF.

Since 2019, BASF has been selling Sulfuric Acid catalyst O4-115 based on the X3D technology. These new shapes have been used in industrial plants with outstanding benefits. For example, replacing one catalyst bed of 1.2 m³ with X3D catalyst results in significant benefits, including caustic soda savings of 20.5 kg/h (equivalent to €58,000 per annum), total annual savings of €100,000, and a higher yield of 1% (equal to 1 MTPD or €25,000 per annum).