Programmable Foam® - extrusion-based 3D printing with TPU
Definition:
Extrusion-based 3D printing, specifically using Thermoplastic Polyurethane (TPU), is an additive manufacturing process where flexible material is deposited layer by layer to create three-dimensional objects with varying degrees of softness and flexibility.
Key components:
- Print head (extruder): Specially designed to handle flexible materials like TPU.
- Build platform: Supports the object being printed. It is heated to improve adhesion.
- TPU filament spool: Supplies the flexible material used in printing.
Materials:
- TPU (Thermoplastic Polyurethane) is known for its flexibility, durability, and ability to withstand wear and tear.
- Multi-hardness variations: TPU filaments are available at different hardness levels, ranging from extra soft to extra hard.
Process:
- Model preparation: Design a 3D model using CAD software.
- Slicing with REALvision Embrace: Convert the model into layers and generate G-code optimized for
- TPU, adjusting settings using modifiers for desired softness or hardness.
- Printing: The printer follows the G-code, extruding TPU material layer by layer.
- Post-processing: Often minimal, may include removing supports or slight surface finishing.
Advantages:
- Customizable flexibility: Ability to print objects with varying multi-hardness levels (extra soft, soft, medium, hard, extra hard).
- Durability: TPU parts are resilient and can withstand repeated use and stress.
- Comfort: Ideal for applications requiring softness and flexibility, such as insoles and wheelchair seating aids.
- Safety: Generally, no need for extensive safety gear during operation.
- Sustainability: Reduces material waste and allows for the use of eco-friendly filaments.
Applications:
- Custom insoles: Personalized insoles with specific multi-hardness for efficient pressure distribution, support, and comfort.
- Wheelchair seats and cushions: Customized seating solutions for enhanced comfort, hygiene, and support.
- Optional medical devices: Soft and flexible parts for various healthcare applications like helmets.
Software:
- REALvision Embrace: A specialized slicer for optimizing TPU printing, allowing precise control over Shore hardness and other print parameters.
Summary:
Extrusion-based 3D printing with TPU using REALvision Embrace slicer offers unparalleled flexibility and customization for professional production. This technology excels in creating custom insoles, wheelchair seating aids with multi-hardness applied. The ability to adjust multi-hardness from extra soft to extra hard makes it ideal for applications requiring tailored comfort and durability. With minimal safety requirements and sustainable practices, this advanced 3D printing approach continues to push the boundaries of soft material manufacturing.
