USA & Canada
USA & Canada
Case Study

Scaling Innovation at The Toro Company Through Automated FDM Support Removal

As additive manufacturing adoption grew across Toro's operations; manual support removal became a bottleneck. By implementing the PostProcess® BASE™ solution, Toro accelerated turnaround times, reduced labor requirements, and improved additive manufacturing throughput.


Additive Manufacturing Simulation for FDM Parts

Why it has been broken for 30 years and how we finally fixed It.

Customer Overview

About The Toro Company

The Toro Company is a global leader in outdoor environment solutions, serving customers in more than 125 countries. To support rapid product development and increasing internal demand, Toro expanded its additive manufacturing operation from a single FDM printer to a fleet of six systems producing prototype and production-scale components.

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Business Challenge

Support Removal Was Slowing Growth

As print volumes increased, Toro's post-processing workflow struggled to keep pace. Support removal often required twice the build time, creating delays and increasing labor requirements. The company’s Minneapolis facility supports more than 300 designers, making efficiency critical to maintaining responsiveness and throughput.

Challenge Highlights

  • Support removal frequently took twice as long as the print itself
  • Significant manual labor for rinsing, soaking, and support removal
  • Post-processing represented approximately 25% of total part cost
  • Growing additive adoption increased workflow bottlenecks
  • Longer lead times limited production efficiency and scalability
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Solution

Automating FDM Post-Processing with BASE

To better align throughput with demand, Toro implemented the PostProcess BASE automated FDM support removal solution in 2019. The software-driven system delivers enhanced consistency, minimizes damaged parts, and dramatically reduces the amount of operator involvement required during support removal.

Key Solution Benefits

  • Automated support removal workflow
  • Recipe-based process control for repeatability
  • Reduced operator intervention
  • Improved part consistency and quality
  • Increased throughput and workflow efficiency

Results

Significant Productivity and Efficiency Gains

By automating support removal, Toro dramatically reduced the time and labor associated with post-processing while supporting continued growth in additive manufacturing applications.

Results at a Glance

  • Average post-printing process times decreased by approximately 89%.
  • Manual labor associated with support removal was reduced by more than 90%.
  • Cleaning and support removal fell from roughly twice the build time to just 4% of build time on average.
  • Support removal activities were reduced to approximately two hours per week for loading, unloading, and rinsing parts

Download the case study

 

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We went from spending two times the build time to clean parts to spending only 4% of the build time on average.

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