BASF commissioned the world’s first production plant for 3D-printed catalysts, bringing its proprietary X3D technology to full industrial scale at its Ludwigshafen site.
The X3D process uses additive manufacturing to produce catalysts with precisely engineered geometries that combine high mechanical stability with an open structure. That design reduces pressure drop inside reactors, increases the catalytically active surface area, and delivers higher reactor throughput at lower energy consumption compared to conventionally made catalysts.
It’s not a debut for the technology itself. BASF has been supplying X3D catalysts to internal and external customers for several years across a range of materials, including precious and base metal catalysts and various support types. The new plant is meant to make the product more widely available and compress the timeline from development to market.
One customer already using the technology is An Hui Jintung, a Chinese fine chemical company that loaded its production plant with BASF’s sulfuric acid catalysts O4-115 X3D in 2025. “The plant started up smoothly, and plant performance has significantly improved compared to before. Production achieved a record high, generating substantial economic benefits for our company. We will continue our collaboration with BASF to promote catalyst upgrades and replacements across additional units,” said Eter Zhu, General Manager at An Hui Jintung.
Detlef Ruff, Senior Vice President Chemical Catalysts and Adsorbents at BASF, said the technology already gives customers a competitive edge. “We can supply catalysts tailored precisely to their specific chemical processes — quickly and in large quantities. At the same time, we help customers reach their goals, as our catalysts enable them to increase production performance while improving the efficiency of the raw materials they use,” he said. Ruff will be succeeded by Yaqian Liu as of April 1.
BASF generated sales of around €60 billion in 2025 and employs around 108,000 people globally. The company is also hosting a virtual trade media briefing in April for journalists who want a closer look at X3D.
Source: basf.com
