BASF Starts Up World's First Industrial-Scale 3D Printed Catalyst Plant

A New Era for Industrial Catalysis

BASF has officially commissioned the world's first industrial-scale production plant for 3D-printed catalysts at its Ludwigshafen site in Germany. This milestone marks a significant advancement in chemical manufacturing, bringing additive manufacturing technology to one of the most critical processes in the chemical industry.

The plant uses BASF's proprietary X3D technology, which produces catalysts with precisely engineered geometries. These custom-designed structures combine high mechanical stability with an open internal architecture, offering several key advantages over traditionally manufactured catalysts.

Why 3D Printing Catalysts Matters

The X3D process allows BASF to create catalysts with intricately designed internal structures that would be impossible to manufacture using conventional techniques. The engineered geometries deliver three major benefits:

• Reduced pressure drop — The open structure allows gases to flow through reactors with less resistance
• Increased active surface area — More surface area means better catalytic efficiency
• Higher throughput at lower energy — Improved efficiency translates to real-world cost savings

"We can supply catalysts tailored precisely to their specific chemical processes — quickly and in large quantities," said Detlef Ruff, Senior Vice President Chemical Catalysts and Adsorbents at BASF. "Our catalysts enable customers to increase production performance while improving the efficiency of the raw materials they use."

Proven Technology

This isn't BASF's first rodeo with 3D-printed catalysts. The company has been supplying X3D catalysts to both internal and external customers for several years, covering various materials including precious and base metal catalysts with different support types.

One early adopter, Chinese fine chemical company An Hui Jintung, installed BASF's O4-115 X3D sulfuric acid catalysts in 2025. According to General Manager Eter Zhu, the plant achieved record-high production output after switching to the 3D-printed catalysts.

What This Means for Industry

The new Ludwigshafen plant represents a shift from R&D prototypes to full-scale industrial production. By bringing manufacturing in-house at this scale, BASF can now offer 3D-printed catalysts to a broader customer base while compressing the timeline from development to market deployment.

With sales of around €60 billion in 2025 and approximately 108,000 employees globally, BASF's endorsement of 3D printing for industrial catalysis could accelerate adoption across the chemical industry.