8 TPU Material 3D Printing Applications You Need To Know

One of the most significant advantages of TPU 3D printing is its excellent shock absorption capabilities. TPU’s unique combination of high elasticity and tensile strength enables it to absorb and dissipate energy efficiently. For instance, ULTRASINT® TPU01 boasts an elongation at break of 280%, making it ideal for applications requiring impact resistance and flexibility. When paired with 3D printing, the lattice structure of TPU material can be adjusted during the design phase to create varying degrees of stiffness and flexibility. A study revealed that optimized lattice structures in TPU material could enhance energy absorption by up to 20%, making the material ideal for customized, high-performance parts tailored to specific needs.

Additionally, ULTRASINT® TPU01 material’s hardness shore rating of 88-90 A strikes a balance between flexibility and firmness, contributing to its effectiveness in reducing impact forces. This material property is critical in applications where maintaining the integrity of the structure while absorbing shocks is essential, such as automotive components and orthopedic supports.

TPU material is known for its exceptional elasticity and rebound properties. Parts made from TPU can stretch significantly under stress and return to their original shape without permanent deformation. ULTRASINT® TPU01 material boasts a rebound resilience rate of 63%, which is considerably higher than many other flexible materials. This high elasticity is particularly beneficial for applications requiring impact resistance and flexibility, such as medical devices, automotive components, and consumer goods. The ability to withstand repeated stretching and compressing without losing integrity ensures that TPU parts maintain their functionality and durability over time.

Another critical advantage of TPU material is its excellent fatigue resistance. Fatigue resistance refers to the material’s ability to endure repeated cycles of stress without experiencing failure or significant degradation. TPU’s resilience against fatigue makes it ideal for applications subjected to constant movement and stress, such as orthopedic insoles, wearable technology, and flexible hoses. This material property ensures the longevity and reliability of TPU components, even in demanding environments, making them a cost-effective and durable choice for engineers and manufacturers.

Orthotics, such as insoles and braces, benefit significantly from TPU 3D printing. With a rebound resilience rate of 63%, ULTRASINT® TPU01 ensures that orthotics can deform and return to their original shape. The material’s resistance to wear and tear aids in extending the lifespan of an orthotic, while offering continuous support during use.

ULTRASINT® TPU01 has a Shore A Hardness rating of 88, providing an ideal balance of stiffness and elasticity to ensure a comfortable, snug fit for insoles. The material exhibits exceptional moisture resistance, preventing the buildup of sweat and bacteria within the insole.

Amputees are often subject to uncomfortable, poorly fitted prosthetic limbs, joints, and sockets. TPU material combines strength and flexibility, enabling a higher degree of functionality to mimic the natural movement of human limbs.

BASF proves the validity of this narrative by 3D printing a perfect-fit prosthetic socket for ProsFit using ULTRASINT TPU01 and ULTRASINT TPU88A. Christopher Hutchinson, Co-Founder of ProsFit, says that before starting this project, “producing and fitting the limb required hours of painstaking and cost-intensive manual work by a prosthetics specialist and several visits to the clinic, meaning the whole process could take several weeks. Using Multi Jet Fusion (MJF) 3D printing technology, ProsFit was able to greatly accelerate the design and production process.

The exceptional vibration cushioning and stability under varying, repetitive stress loads enable ULTRASINT TPU to maintain its mechanical characteristics without showing any performance or visual degradation over time.

The automotive industry demands materials that can withstand harsh conditions while maintaining performance. TPU is widely used in manufacturing flexible hoses and pipes for automotive applications due to its excellent resistance to oil, grease, and abrasion.

TPU hoses and pipes offer long-lasting performance in fuel and hydraulic systems, where durability and reliability are critical. With a material melting temperature varying between 248 – 302 °F, TPU maintains flexibility under varying temperatures and pressures.

TPU material is an ideal solution for manufacturing interior car components with complex 3D-printed geometries. The design of car seats demands a material that encompasses both flexibility and functionality. Given TPU 3D printing’s ability to manipulate the lattice structure during the design phases, engineers can 3D print car seats with varying flexibility.

BASF brings this to light when developing an innovative, open lattice structure car seat design for Citroën. The design provides natural airflow while maintaining the structural integrity to withstand long car rides. Similarly, BASF created car headrests, leveraging TPU material’s elasticity to conform the headrest to a person’s head. This adaptability ensures that the seating remains comfortable regardless of the passenger’s size or seating position, promoting better posture and reducing fatigue.