<p id="isPasted">Designing medical parts? Just as there are countless types of medical procedures, there are also countless types of polymers on the market today. Which ones are best for your medical application? Great question. We’ll attempt to provide some guidance in this design tip, but it’s important to start with the following caveat: The term “medical grade” is ambiguous at best. &nbsp;</p><p><a href="https://www.protolabs.com/en-gb/industries/medical/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-1224&utm_content=wevolver-medical-plastics-1224" title="Medical" target="_blank" rel="noopener noreferrer">Medical device</a> manufacturers must understand and comply with a slew of standards, but for the purposes of this discussion, ISO 10993 takes the lead role. It has nearly two dozen parts, of which four pertain specifically to material selection; of these, ISO 10993-13 is probably the most relevant to polymers.&nbsp;</p><p>Unfortunately, there’s no catalogue or book that lists which polymers meet which standards, or even which polymers are biocompatible. Compounding matters is the sheer number of resins, pellets, powders, and bulk forms like rod and sheet from which to choose, each with multiple manufacturers that may or may not meet the necessary&nbsp;<a href="https://www.protolabs.com/en-gb/resources/design-tips/manufacturing-tool-kit-for-the-medical-industry/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-1224&utm_content=wevolver-medical-plastics-1224" title="Manufacturing Tool Kit for the Medical Industry" target="_blank" rel="noopener noreferrer">medical device requirements</a>. Where one might provide medical-grade ABS, the other produces ABS suitable for LEGOs and power tool housings. &nbsp;</p><p>Of course, one blog post can’t cover all you need to know about medical grade plastics, so don’t forget you can look at the stats on our <a href="https://www.protolabs.com/en-gb/materials/comparison-guide/?category=plastic&utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-1224&utm_content=wevolver-medical-plastics-1224" title="Comparison Guide" data-anchor="?category=plastic" target="_blank" rel="noopener noreferrer">materials comparison page</a>. All that said, here are six essential polymers to keep in mind for your next medical parts project.&nbsp;</p><h3 id="isPasted">Comparing Plastics for Medical Parts&nbsp;</h3><p>Generally, medical device designers and manufacturers should look for polymers that are resistant to corrosion, chemical attack, and high temperatures. These should be non-absorbent and inert, and able to withstand repeated sterilisation cycles in an autoclave. Of course, they shouldn’t react with bodily fluids and human tissue, cause irritation, or create skin sensitivities. Did we mention strength and durability? All of this might seem like a very tall order, but the good news is that a healthy handful of polymers check at least most of these boxes. &nbsp;</p><h5 id="isPasted"><strong>PC</strong>&nbsp;</h5><p>Oftentimes, an optically transparent polymer is needed for medical procedures, and polycarbonate is the material of choice. It checks all the usual boxes in terms of toughness, dimensional stability, heat and chemical resistance, and sterilizability. You won't find it inside the human body, but PC is typically used when it's necessary to see blood, drugs, and other fluids flowing through a device. Many of Protolabs' medical customers will 3D-print their designs from PC-like materials such as Acura 5530 or PerFORM, then go on to machined or injection-moulded polycarbonate as production needs increase. &nbsp;</p><h5 id="isPasted">UHMW-PE&nbsp;</h5><p>Since we’re discussing orthopedic implants, here’s another important polymer to keep in mind: ultra-high molecular weight polyethylene. If you’ve had a knee or hip replacement, chances are good that you have some of this stuff inside you. UHMW-PE is an extremely dense, low-friction member of the polyethylene family. If you’re looking for some machined medical components (or wear-resistant machinery parts), UHMW-PE has excellent impact strength and abrasion resistance, and here again, is eminently biocompatible. And for slightly less demanding applications, “regular” polyethylene (PE) and high-density polyethylene (HDPE) are good, all-around polymers for a wide range of medical applications, especially for single-use products and the PPE gear that’s become so prevalent over the past few years. &nbsp;</p><h5 id="isPasted"><strong>PEI</strong>&nbsp;</h5><p>Like PEEK, polyetherimide borders on super-polymer territory. Better known by its trade name Ultem, PEI is a rigid, semitransparent, and heat-resistant 180°C polymer that is amber in colour and boasts great tensile strength. Because it also has high dielectric characteristics and resistance to flame, it is widely used in electronic components, medical or otherwise. We machine and injection mould PEI into various shapes, with potential uses including handles for surgical instruments, medical device enclosures, insulators, electrical connectors, and more. Lastly, PEI is readily sterilised via autoclaving and gamma radiation. &nbsp;</p><h5 id="isPasted"><strong>PSU</strong>&nbsp;</h5><p>Another amber-coloured polymer is PSU, short for polysulfone. Recognised for its toughness and rigidity at elevated temperatures, PSU is less strong than PEI but more impact resistant. It might be machined or moulded into filter housings, catheter ports, surgical instrument trays, and sizing devices for use during heart valve replacements. Polysulfone is said to be one of the few polymers able to withstand more than 1,000 cycles of steam sterilisation (as can PEEK and PSU’s even more impact- and heat-resistant cousin, polyphenylsulfone, or PPSU).&nbsp;</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734519080624-1734519080624.png" class="fr-fic fr-dib" style="width: 806px;"></p><p><em>This medical component from IDEXX Laboratories, Inc. is part of an instrument that veterinarians use to test blood and urine.</em></p><p><em><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734519116565-1734519116565.png" style="width: 808px;" class="fr-fic fr-dib"></em><em>Moluded part manufactured with medical-grade liquid silicone rubber.</em></p><h5 id="isPasted"><strong>PEEK</strong>&nbsp;</h5><p>Polyetheretherketone is a great place to start. Long considered an “engineering-grade” thermoplastic, PEEK enjoys broad use in the medical industry. Orthopedic surgeons use it for trauma fixation, spinal implants, and replacement joints, while dentists use it in crowns and bridges. PEEK is both lightweight and strong, is radiopaque (meaning it appears on x-rays), and maintains its strength and dimensional stability at high temperatures. And seeing that PEEK is often inserted into the human body for extended periods of time, it goes without saying that it’s biocompatible and sterilisable. Protolabs routinely CNC machines and plastic injection moulds PEEK into mechanical components such as gears, bearing surfaces, and manifolds, as well as a host of medical parts. &nbsp;&nbsp;</p><h5 id="isPasted"><strong>Silicone</strong>&nbsp;</h5><p>The stuff of weatherproofing adhesive and cooking utensils, silicone is also an excellent choice for many medical components. Silicone is available in various hardness levels, from soft and stretchy like a rubber band or rigid like a tire tread. It withstands temperatures from sub-zero to oven hot 55°C to 210°C, is hydrophobic (repels water), resistant to solvents and acids, and has good vapour permeability, making it a favourite for prosthetic devices. Protolabs 3D-prints a variety of medical components, including seals, gaskets, and surgical models, and injection moulds all manner of prototypes and end-use production parts using liquid silicone rubber (LSR). You can even 3D print in silicone, a great option for prototyping parts using this material for complex parts or prior to moving to injection moulding for production quantities. In addition, there’s also an optical grade of liquid silicone rubber, OSLR, which enjoys superior refractive and light transmission properties compared to its PC or PMMA (acrylic) alternatives. It is therefore popular for use in lenses and lighting applications, or anywhere that a clear, non-yellowing, heat- and chemical-resistant biocompatible polymer is needed. &nbsp;&nbsp;</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734519177098-1734519177098.png" class="fr-fic fr-dib"></p><p><em>An operator removes a silicone part from the LSR press. Due to the elasticity of silicone parts, manual removal is necessary.</em></p><h3 id="isPasted">More Options to Consider&nbsp;</h3><p>Those six medical-grade polymers are just the starting point. We’d be remiss if we didn’t mention PTFE, better known as Teflon, a super-lubricious polymer used in everything from catheters and stents to heart-lung machines. Impact and chemical-resistant acrylonitrile butadiene styrene (ABS) is sometimes used to replace metal structural components in medical equipment, as is acetal (you might know it as Delrin), while polyvinyl chloride (PVC) might be considered a flexible version of polycarbonate in certain applications. Polyethylene terephthalate (PET) resists attacks by microorganisms, making it just as suitable for soft drink containers as it is for wearable sensors. Polypropylene (PP)—although considered a commodity plastic—finds widespread use in specimen bottles, prescription containers, and disposable hypodermic syringes (it’s also a great option for parts that would benefit from a living hinge). &nbsp;</p><p>As with any manufacturing application, choosing the best material for a medical device comes down to its physical, chemical, and electrical requirements, not to mention its operating environment. There’s also manufacturability to consider and all the design rules that go along with that. And at the end of the design and prototyping process waits the FDA approval ordeal. It can be a confusing landscape to navigate, which is why we encourage you to upload a file, get a quote, and give us a call to discuss your options. We've helped countless others who were once in your shoes. &nbsp;</p>

Safety and longevity are key to this list of medical-grade plastics.

Plastics for Medical Devices and Applications

<p id="isPasted">We’ve recently covered the&nbsp;<a href="https://ultimaker.com/learn/benefits-of-3d-printing-in-manufacturing/">benefits of 3D printing in manufacturing</a> where we outlined how in today’s fast-paced manufacturing environment, operational efficiency and adaptability are more critical than ever.</p><p>Whether you're an operations manager looking to streamline production workflows or an engineer tasked with solving complex design challenges, 3D printing has become a transformative tool in modern manufacturing.</p><p>This article will explore&nbsp;<strong>how 3D printing is being applied across the manufacturing industry</strong>, from custom tooling and rapid prototyping to on-demand spare parts production, highlighting real-world examples and key benefits for professionals striving to maintain a competitive edge in their operations.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507534509-0H6A3681-2.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h2>Custom Jigs, Fixtures, and Tooling</h2><p>Across the entire manufacturing landscape, jigs, fixtures, and tooling play a pivotal role in ensuring product quality, assembly accuracy, and production speed. Traditionally, creating these components required time-intensive machining and significant costs, especially for customized solutions. 3D printing allows for a vastly more rapid, efficient, and cost-effective way of producing these parts.</p><p>Several of our clients such as ERIKS, Volkswagen Autoeuropa, Zeiss, and IME Automation have already implemented 3D printing technology to create various jigs and fixtures to streamline and improve their manufacturing capabilities.</p><p>Here’s a few examples:</p><h3>ERIKS - Motor and drill alignment jigs</h3><p>The implementation of the motor jig, for example, allowed for an easier assembly of the components minimizing the chance of assembly errors while also making the process 3 times faster (assembly time previously took around 3 minutes which was cut down to one).</p><p>According to ERIKS:</p><blockquote><p>For us the primary benefit of 3D printing is speed. How quickly can we get something? And that is where 3D printers are the fastest option you can get. I can turn on a print job at 2 pm one day, and the next morning I come into the office and now I have the tools ready. So that is the main factor why we choose 3D printing over conventional methods, whenever we can. Cost is a side benefit for us.</p></blockquote><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507587853-1734507587853.png" class="fr-fic fr-dib"></p><h3 id="isPasted">Volkswagen Autoeuropa - Manufacturing tools</h3><p><a href="https://ultimaker.com/learn/volkswagen-autoeuropa-maximizing-production-efficiency-with-3d-printed-tools-jigs-and-fixtures/">Volkswagen Autoeuropa</a> has switched to 3D printing in order to produce the vast majority of tools used in their manufacturing line and has seen tool development time reduced by up to 95% and costs by 91% (saving an estimated $375.000 per year).</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507613298-1734507613298.png" class="fr-fic fr-dib"></p><h3 id="isPasted">Zeiss - Adapter plate and label placement gauge</h3><p>For&nbsp;<a href="https://ultimaker.com/learn/zeiss-precision-parts-for-serial-production/">Carl Zeiss Optical Components</a>, precision is paramount when manufacturing microscopes, multi-sensoric machines and optical sensors for industrial measurement and quality assurance purposes.</p><p>Their implementation of <a href="https://ultimaker.com/">UltiMaker’s 3D printing</a> technology not only enabled them to create bespoke adapter plates for each of their microscopes in serial production streamlining the process but also made supporting those parts for their clients a lot easier, as spares could be printed on demand and sent to a client’s location. Previously they had to produce several parts, mount them together, and adjust them which was a more costly and time-consuming process.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507633041-zeiss-adapter-plate-ultimaker-1.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">Taking label placement gauges as another example, previously made out of POM (polyoxymethylene), the sharp corners would lead to breakage if dropped. Adding in the fact that POM is traditionally made by injection molding or extrusion, itself a costly process, would often require CNC machining to create the desired part.</p><p>In contrast, the new 3D printed gauges allowed products to slide in and out of the tool effortlessly while also being less fragile, more wear-resistant and could be printed to achieve tight tolerances, all while having a print time of just 3 hours at €2.20 per part.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507646971-Zeiss.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 id="isPasted">IME Automation - Box folding jig</h3><p>With a focus on precision, efficiency, and innovation in the field of building custom automated robotics for manufacturers<a href="https://ultimaker.com/learn/3d-printing-for-flexible-manufacturing-with-ime-automation/">&nbsp;IME Automation turned to 3D printing</a> to test and create a wide range of applications to be more agile and flexible in their manufacturing process.</p><p>One of the most notable examples is the one that started them on the path of using 3D printing technology, their patented box folding jig.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507662261-Copy-of-IME-Sparky-close-up-1.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">Used to erect or fold cartons their customers previously had to either buy an off-the-shelf carton erector or a full-fledged cartoner which were big, cost prohibitive, and offered no flexibility to changes due to the long times required to adapt them.</p><p>The 3D printed folding box jig IME Automation developed was a game changer as they could iterate a wide variety of shapes and sizes with less than 2-minute part changeover times.</p><h2>Rapid Prototyping and End-Use Parts Production</h2><p>As previously hinted, 3D printing allows for direct fabrication of prototypes from CAD models, bypassing the need for complex tooling or molds. This capability significantly shortens development cycles and enables designers to test, modify, and validate designs with a high degree of speed and flexibility.</p><p>Unlike traditional subtractive manufacturing processes, additive manufacturing allows for the creation of designs with complex geometry, overhangs, and organic shapes at a reduced cost and complexity. This innate feature allows 3D printing to bridge the gap between prototyping and large-scale production, allowing companies to produce end-use parts without the need for expensive and time-consuming tooling. Our clients Sylatech and Snow Business offer some great examples in this regard:</p><h3>Sylatech - Yacht propeller prototype</h3><p>An investment casting firm, Sylatech was previously unable to test design functionality without using tooling investment casting, a time-consuming and costly process, typically taking three to four weeks with customers paying £2,000-4,000 per tool. Add in the fact that approximately 30% of tools require some sort of alteration, which can cost up to £900, it’s easy to see why they needed a solution to reduce lead times and costs.</p><p>Using UltiMaker’s 3D printing technology they were able to reduce the development time of a yacht propeller from four weeks to just three days and brought down the total cost from £17,100 to £15,660 (including casting tooling costs).</p><p>Taking into account that with 3D printing only 5% of tools needed alteration, Sylatech’s ROI for an UltiMaker 3D printer was less than 3 months.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507676679-yacht-propeller-and-prototype-image.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 id="isPasted">Snow Business - Snow machine nozzle</h3><p>With over 35 years of experience in the artificial snow industry for film and TV effects production, Snow Business has leveraged 3D printing to prototype, functionally test and create final parts for their machines. For example, the nozzles on their snow machines could be 3D printed in-house within seven hours at £2.50 each, negating the need for an SLS service which took up seven days with a minimum £125 per order. They estimate that their UltiMaker printer paid for itself within just two weeks.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507691141-snow-business-ROI-calculator.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 id="isPasted">On-Demand Spare Parts and Maintenance</h2><p>In traditional manufacturing, maintaining a stock of spare parts for machinery or production lines often requires significant investment in inventory and storage space. Long lead times for replacement parts can result in costly production delays.</p><p>3D printing eliminates these challenges by enabling the on-demand production of spare parts directly on location, aside from the greater flexibility and cost efficiency in maintenance operations, manufacturers can leverage 3D printing to also extend the lifespan of existing machinery far beyond the OEM’s support cycle which is an often underreported benefit that directly translates to lower production costs and higher production uptimes.</p><p>Some of our clients, such as Trivium and Heineken, have integrated UltiMaker’s ecosystem precisely for this reason:</p><h3>Trivium - Conveyor infeed worm and silicone seals &amp; gaskets</h3><p>In Trivium’s case, the original packaging machine had worn out and was no longer available from the supplier and manufacturing it via traditional methods such as CNC milling was cost prohibitive and time consuming. 3D printing the part in a low cost material such as ABS allowed them to validate the design and switching to carbon reinforced nylon netted them a durable replacement part that allowed them to keep their production rolling.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507706706-image.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">Similarly, the molds needed for silicone seals and gaskets needed for different machines were either too expensive or, as was the case for the infeed wheel, no longer available.</p><p>Using ABS printed with a 60 micron layer height, Trivium was able to cleare smooth and accurate molds for silicone which could be reused and reprinted on demand, saving time and money.</p><h3>Heineken - Stopper tool</h3><p>After the implementation of 3D printing technology in their Seville plant, Heineken was able to improve their manufacturing process in terms of output, uptime, and safety. We recommend reading further on&nbsp;<a href="https://ultimaker.com/learn/heineken-ensuring-production-continuity-with-3d-printing/">how Heinken ensured production continuity with 3D printing</a> for a more comprehensive list of applications, but for this example, we want to showcase their stopper tool.</p><p>As a custom tool used to loosen or tighten the columns for the guiding wheels that apply bottle labels, the 3D printed version of the tool was 70% cheaper to produce than the previously CNC machined one and done within a single day instead of three.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507722244-heineken-ultimaker-3d-printed-tools-speed-up-maintenance-.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 id="isPasted">Materials Enabling Versatility in Manufacturing</h2><p>UltiMaker’s ecosystem of advanced printing solutions provides manufacturers with the flexibility to choose from a wide range of materials tailored to specific applications. From durable industrial plastics to flexible polymers, these materials enable the production of functional parts that can withstand the rigors of industrial environments even replacing traditional materials such as aluminum or steel in certain applications without compromising on part reliability or function.</p><p>As a reference starting point here are 3 of the materials used in the above examples:</p><p><a href="https://marketplace.ultimaker.com/app/cura/materials/UltimakerPackages/UltimakerTPLA">UltiMaker Tough PLA</a>:</p><ul><li><strong>Applications:</strong> Strong and impact-resistant parts such as jigs, fixtures, and prototypes.</li><li><strong>Use case:</strong> Heineken uses Tough PLA to print durable production line components, including bottle guides and tool organizers, ensuring longevity while maintaining cost-effectiveness</li></ul><p><a href="https://marketplace.ultimaker.com/app/cura/materials/UltimakerPackages/ULTIMAKERNYLON12CFMETHOD">UltiMaker Nylon CF</a></p><ul><li><strong>Applications:</strong> High-strength, abrasion-resistant parts like gears, bushings, and conveyor belts.</li><li><strong>Use case:</strong> Trivium Packaging leverages carbon reinforced nylon for parts like conveyor infeed worms, which must endure high wear and tear in a manufacturing environment</li></ul><p><a href="https://marketplace.ultimaker.com/app/cura/materials/UltimakerPackages/UltimakerABS">UltiMaker ABS</a></p><ul><li><strong>Applications:</strong> Durable parts requiring smooth surface finishes, such as molds and protective covers.</li><li><strong>Use case:</strong> Zeiss’s adapter plates and label placement gauges are both made from ABS.</li></ul><p>We recognize that material selection is one of the cornerstones of successful 3D printing applications in manufacturing and with a selection of over 200+ materials on the Marketplace, we’ve recently expanded the possibilities available on a single print with our dual-extrusion&nbsp;<a href="https://ultimaker.com/3d-printers/factor-series/ultimaker-factor-4/">Factor 4 printer</a>:</p><ul><li><strong>Support Materials:</strong> Soluble supports like PVA allow for complex geometries with overhangs or internal structures that would otherwise be impossible to produce through traditional methods.</li><li><strong>Composite Structures:</strong> Pairing flexible materials like TPU with rigid materials like nylon creates parts with hybrid properties, such as flexible joints or shock-absorbing elements.</li></ul><h2>IMES3D - The Power of Partnership</h2><p>For a holistic view of how UltiMaker’s complete ecosystem can help manufacturers and businesses integrate 3D printing technologies into their workflows effectively, we turn to <a href="https://ultimaker.com/learn/imes3d-expert-support-for-industry-level-3d-printing/">IMES3D</a>, one of our clients and partners, as an example of leading the charge in the transformative nature of 3D printing technology.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507740966-imes3d.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">Offering professional support and a full suite of comprehensive services, IMES3D specializes in designing and implementing 3D printing solutions tailored to their customers specific operational needs. From printing parts and support in selecting the right materials they also offer consulting services for companies looking to adopt additive manufacturing and integrate it into existing workflows.</p><p>In order to support their clientele spanning a wide range of industries, including automotive, food and beverage, military and medical sectors, they rely on UltiMaker’s unique ecosystem to ensure that their 60+ printer fleet is utilized as efficiently as possible.</p><p>Elaborating on UltiMaker’s ecosystem this is comprised of 3 main parts:</p><p><strong>Hardware:</strong></p><ul><li>S Series</li><li>Method Series</li><li>Factor Series</li></ul><p><strong>Software:</strong></p><ul><li>Cura</li><li>Digital Factory</li></ul><p><strong>Materials &amp; Partners:</strong></p><ul><li>UltiMaker materials</li><li>3rd party partner materials</li></ul><p>Along with UltiMaker Cura which is a fast and easy-to-use slicer, Digital Factory is used to easily manage all of the printers in the network, and ensure that projects get sent to the right printer and queues are monitored. Additionally, some customers have also started using Digital Factory which enables IMES3D to leverage the software as a key support tool being able to remotely send and queue prints from their facility.</p><p>Their expertise spans technology, material science, and production optimization, which is why we highly recommend watching our&nbsp;<a href="https://ultimaker.com/learn/how-imes3d-unlocks-industrial-3d-printing-with-the-ultimaker-ecosystem/">recent webinar with IMES3D</a> to get a full picture of how they are advancing industrial 3D printing together with UltiMaker’s ecosystem.</p><p>But for those interested in a couple of short granular examples of applications we’d like to showcase two that were made possible with the addition of the new UltiMaker Factor 4 printer:</p><h3>Flexible bumpers for PDA’s</h3><p>Considering that most PDA manufacturers do not make any protective covers for their devices, resulting in drastically reduced lifespans due to accidental drops or mishandles, IMES3D designed and printed a wide variety of custom bumpers made out of soft TPU filament.</p><p>The ability to print in a variety of colors also allowed IMES3D to color code the bumpers according to their customer’s specifications.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507763014-1734507763014.png" class="fr-fic fr-dib"></p><h3 id="isPasted">Mold for part injection</h3><p>The ability to print in UltiMaker’s new PPS CF carbon reinforced filament, opened up the possibility of replacing metal parts with the new composite material. With extreme durability and high-temperature resistance (HDT B of over 230°C printing), IMES3D was able to create a mold connector used for injecting parts for water and air pipes.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507784011-imes3d-1.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 id="isPasted">Become an industry leader with UltiMaker</h2><p>3D printing is not merely a complementary technology, it is reshaping the manufacturing landscape. At the cutting edge, UltiMaker’s Factor 4 empowers companies to innovate rapidly, cut costs, and create complex designs and paves the way for a more agile and efficient future.</p><p>If you want to know how UltiMaker can help you change the game for your business don’t hesitate to&nbsp;<a href="https://ultimaker.com/quote-request/">contact us</a> and our team of experts would be more than happy to reach out!</p>

This article will explore how 3D printing is being applied across the manufacturing industry, from custom tooling and rapid prototyping to on-demand spare parts production, highlighting real-world examples and key benefits for professionals striving to maintain a competitive edge in their operations

Applications of 3D Printing in Manufacturing

<p data-pm-slice="1 1 []" id="isPasted"><strong>Let's start with the Properties of Aluminum AlSi10Mg (3.2382)</strong></p><p><strong>1. High Strength and Hardness:</strong> AlSi10Mg is renowned for its high strength and hardness. The addition of magnesium and silicon enhances its mechanical properties, making it suitable for applications that require both durability and strength.</p><p><strong>2. Good Thermal Properties:</strong> The alloy exhibits excellent thermal conductivity, which is crucial for applications in high-temperature environments. This property makes it effective in managing heat dissipation, especially in components subjected to thermal stresses.</p><p><strong>3. Good Processability:</strong> The presence of silicon in AlSi10Mg improves the viscosity of the melt pool during additive manufacturing. This enhances the alloy's processability compared to pure aluminum, allowing for more precise and efficient 3D printing.</p><p><strong>4. High Corrosion Resistance:</strong> AlSi10Mg offers excellent resistance to corrosion, which is essential for parts exposed to harsh environments. This property ensures the longevity and reliability of components, especially in aerospace and automotive applications.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734430992551-2-min.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p><br></p><p><strong>Applications of Aluminum AlSi10Mg (3.2382)</strong></p><p><strong>1. Aviation and Aerospace:</strong> In the aerospace industry, AlSi10Mg is valued for its high strength-to-weight ratio, thermal conductivity, and corrosion resistance. It is commonly used in structural components, engine parts, and other critical applications where performance and reliability are paramount.</p><p><strong>2. Automotive:</strong> The alloy is used in automotive parts where high strength and lightweight properties are essential. It is particularly useful for producing parts that need to withstand stress while contributing to overall vehicle efficiency.</p><p><strong>3. Prototype Cast Parts:</strong> AlSi10Mg is ideal for producing prototype cast parts. Its good processability and mechanical properties make it suitable for creating functional prototypes that can be tested in real-world conditions.</p><p><strong>4. Serial Parts:</strong> The alloy is also used in serial production, where it can be employed to manufacture components in bulk. Its ability to maintain strength and quality over large production runs makes it a popular choice for various serial applications.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734430973728-1-min.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p><br></p><p><strong>Physical and Mechanical Properties</strong></p><p><strong>Tensile Strength:</strong> In its as-built condition, AlSi10Mg exhibits a tensile strength of approximately 400 N/mm². This high strength ensures that parts made from this alloy can endure significant stresses and loads.</p><p><strong>Heat Treatment:</strong> The alloy can undergo a P6 heat treatment process to achieve enhanced ductility. This treatment allows for improved performance in applications where flexibility and resistance to cracking are important.</p><p><br></p><p><strong>To sum it up..</strong></p><p>Aluminum alloy AlSi10Mg (3.2382) stands out in metal 3D printing for its high strength, good thermal properties, and excellent processability. Its suitability for aviation, automotive, and prototype applications highlights its versatility and reliability. As industries continue to innovate and push the boundaries of material performance, AlSi10Mg remains a key material, offering a blend of strength, processability, and durability for a wide range of advanced manufacturing needs.</p>

AlSi10Mg (3.2382) is a high-performance material widely used in metal 3D printing for various advanced applications. Let's take an in-depth look at its properties, applications, and mechanical characteristics.

Aluminum AlSi10Mg (3.2382) in Metal 3D Printing: Key Insights

In this guide, we cover all the different types of polymer FDM 3D printing filament, from standard grades like PLA and ABS to advanced high-performance filaments like PEEK and fiber-reinforced materials.

What Material Is Used for 3D Printing? A Guide to Polymer FDM Filaments

<h2 id="isPasted">Understand the Future of Metal 3D Printing</h2><p>The <strong>Metal 3D Printing Technology Report</strong> is your essential guide to the latest advances, applications, and real-world insights into additive manufacturing with metal. Packed with detailed case studies, &nbsp;practical information, and interviews with industry leaders, this report reveals how metal 3D printing is transforming industries and pushing the boundaries of manufacturing.</p><p>Read the intro to the report <a href="https://www.wevolver.com/article/metal-3d-printing-technology-report">here</a> and an excerpt from chapter 4 below.&nbsp;</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734355340345-froala_1733828027720-5%2BRising%2BTrends%2Bfor%2BAI%2BAdoption%2Bin%2BManufacturing%2B%281920%2Bx%2B500%2Bpx%29.png" style="width: 100%px;" class="fr-fic fr-dib"></p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe id="JotFormIFrame-243032488553458" title="Metal 3D Printing Report" allowtransparency="true" src="https://form.jotform.com/243032488553458" frameborder="0" style="min-width: 100%; max-width: 100%; height: 690px; border: none;" scrolling="yes" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"> </iframe></span></p><h2 dir="ltr">Introduction</h2><p dir="ltr" id="isPasted">Metal 3D printing opens up design opportunities due to its high level of geometrical freedom. However, like all technologies, it requires design for manufacturability (DFM) considerations, taking into account the physical constraints of the equipment and materials. In 3D printing, this design strategy is referred to as design for additive manufacturing (DfAM). Most major CAD software providers provide DfAM tools (as well as 3D printing simulation tools), as 3D printing hardware is now widespread.</p><h3 dir="ltr">Design opportunities</h3><p dir="ltr">Compared to other metal manufacturing processes like machining, casting, and forging, 3D printing offers a number of design advantages, including:</p><ul><li dir="ltr"><p dir="ltr">Design freedom: Designs are unhindered by cutting tool access and other conventional manufacturing constraints; limitations (e.g. support structures to support overhangs) are minimal in comparison.</p><ul><li dir="ltr"><p dir="ltr">Multi-axis design freedom: Some DED systems offer multi-axis material deposition, enabling printing of unsupported overhangs and further design freedom.</p></li></ul></li><li dir="ltr"><p dir="ltr">Internal structures: Additive process allows for complex internal geometries and precise density control, giving a high level of control over part strength, weight, flexibility, and other characteristics, as well as allowing for cooling and fluid flow channels.</p></li><li dir="ltr"><p dir="ltr">Lightweighting: Partly hollow designs allow for lightweighting of parts that would otherwise be conventionally manufactured.</p></li><li dir="ltr"><p dir="ltr">Organic shapes: Generative design software can create complex, interlocking, or curved parts that mimic organic shapes.</p></li><li dir="ltr"><p dir="ltr">Part consolidation: Metal 3D printing can be used to consolidate assemblies into simple parts, increasing production efficiency, improving performance, and increasing part service life.</p></li></ul><h3 dir="ltr">Design limitations</h3><p dir="ltr">Metal 3D printing offers a high level of design freedom, but it suffers from a handful of limitations. Some of these are technology-specific. For example, design for metal extrusion is governed by the limitations of both polymer extrusion printing and part sintering. Some limitations in metal 3D printing design include:</p><ul><li dir="ltr"><p dir="ltr">Thermal stresses: Since most metal 3D printing technologies require high temperatures, part design must minimize thermal stresses. This may be achieved by introducing corner radii, avoiding thin sections, etc.</p></li><li dir="ltr"><p dir="ltr">Shrinkage: Several metal 3D printing technologies require sintering, which results in part shrinkage as voids are removed. This should be factored into design to ensure part dimensions fall within acceptance tolerances.</p></li><li dir="ltr"><p dir="ltr">Trapped powder: Powder bed processes can result in powder trapped within hollow sections unless design allows the powder to escape.</p></li><li dir="ltr"><p dir="ltr">Overhangs, bridges, supports: Supports are often required to support overhangs and bridges. Top-heavy or unbalanced designs may sag or deform during sintering or heat treatment.</p></li><li dir="ltr"><p dir="ltr">Feature size: Processes like extrusion and binder jetting have a limited minimum feature size.</p></li></ul><h2 dir="ltr">Tools for DfAM</h2><p dir="ltr">Advanced CAD software may include tools for metal 3D printing design such as design validation, performance analysis, lattice generation, and topology optimization. Simulation tools for validating designs may be incorporated into CAD, CAE, CAM, or distinct process simulation software. Simulation of 3D printing processes typically involves advanced thermal modeling. Research shows that both topology optimization and generative design tools can be adopted at the early stages of 3D printing design to either create a geometry driven by functional requirements or to redesign components to make them lighter and stronger.</p><h3 dir="ltr">Generative design</h3><p dir="ltr">Generative design is the use of algorithmic software to create novel designs based on user-defined constraints. It is generally employed during the conceptual design stage. While generative design is not unique to metal 3D printing, metal 3D printing is one of the few processes that can easily realize a broad range of generated designs. Altair Sulis is one example of a DfAM tool that uses generative design to generate AM-optimized designs.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733927613980-design+for+metal.png" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">3D Systems company Oqton’s 3DXpert industrial 3D printing software. Image credit:&nbsp;<a href="https://oqton.com/posts/3dxpert-space-exploration/" id="isPasted">Oqton</a></span></span></span></p><h3 dir="ltr">Topology optimization</h3><p dir="ltr">Topology optimization is a design strategy for optimizing the structure of a printed part, generally to reduce weight while maintaining strength. Unlike generative design, it is used to optimize specified shapes instead of creating designs from scratch. As with generative design, however, the freeform nature of 3D printing means that most designs can be realized. Software such as 3D Systems 3DXpert provides topology optimization tools for metal printing.</p><h3 dir="ltr">Lattice generation</h3><p dir="ltr">Lattice structures are a key feature of metal 3D printing as they serve to maximize strength and minimize mass and cannot easily be produced using other manufacturing processes. Software can be used to automatically generate printable lattice structures within predefined boundaries. Siemens NX CAD is an example of an application that incorporates lattice generation for metal 3D printing design.</p><h2 dir="ltr">Get your report now</h2><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734355363801-froala_1733828027720-5%2BRising%2BTrends%2Bfor%2BAI%2BAdoption%2Bin%2BManufacturing%2B%281920%2Bx%2B500%2Bpx%29.png" style="width: 100%px;" class="fr-fic fr-dib"></p><p dir="ltr" id="isPasted"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe id="JotFormIFrame-243032488553458" title="Metal 3D Printing Report" allowtransparency="true" src="https://form.jotform.com/243032488553458" frameborder="0" style="min-width:100%;max-width:100%;height:690px;border:none;" scrolling="yes" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"> </iframe></span></p><p><a href="https://www.wevolver.com/article/metal-3d-printing-technology-report"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734355421527-1734355421527.png" class="fr-fic fr-dii"></a></p><p><br></p><p id="isPasted"><a href="https://www.wevolver.com/article/chapter-1-core-metal-3d-printing-technologies"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734355370353-1734355370353.png" class="fr-fic fr-dii"></a></p><p><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-1-core-metal-3d-printing-technologies"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734355370459-1734355370459.png" class="fr-fic fr-dii"></a></p><p><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-3-post-processing-for-metal-am"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734355370376-1734355370376.png" class="fr-fic fr-dii"></a></p><p><br></p>

Metal 3D printing offers significant design opportunities with its high geometrical freedom, but it requires careful design for additive manufacturing (DfAM) to address equipment and material constraints, a process supported by DfAM and 3D printing simulation tools in most major CAD software.

The Metal 3D Printing Technology Report: Chapter 4: Design for Metal 3D printing

From entry-level FDM machines to industrial-grade metal printers, this guide demystifies the many types of 3D printers available to businesses and consumers.

Types of 3D Printers: The Ultimate Guide to Additive Manufacturing Technologies

<p data-pm-slice="1 1 []" id="isPasted"><strong>Producing Medical parts with a Metal 3D printer</strong></p><p>Metal 3D printing is opening new avenues in the medical field, particularly for producing custom implants and prosthetics with high precision. It enables the creation of complex structures, such as porous designs that support bone growth, which are difficult to achieve with traditional manufacturing techniques. Additionally, the use of materials like titanium, known for its strength and biocompatibility, makes 3D printing ideal for medical applications. The technology offers an efficient way to produce both custom and serial parts, supporting advancements in patient care through more personalized solutions.</p><p><br></p><p><strong>MDE prints medical devices with two One Click Metal systems</strong></p><p>The Italian medical device manufacturer <a href="https://www.mde-rd.com/en/" target="_blank" rel="noopener noreferrer">MDE</a>, based in Brescia, Italy specializes in the production of medical devices and supports clients through the R&amp;D phase and prototyping. The company started with one <a href="https://oneclickmetal.com/boldseries/" target="_blank" rel="noopener noreferrer">3D printing system</a> from One Click Metal to print medical devices and prototypes in stainless steel. Recently they invested in a second system. The second system is dedicated to titanium, and further enlarges MDE‘S capacities to produce high-quality medical-grade components.</p>

The italian company MDE shows how they are using metal 3D printing in their daily business. 

Metal 3D printing in the medical field

<h2 id="isPasted">Understand the Future of Metal 3D Printing</h2><p>The <strong>Metal 3D Printing Technology Report</strong> is your essential guide to the latest advances, applications, and real-world insights into additive manufacturing with metal. Packed with detailed case studies, &nbsp;practical information, and interviews with industry leaders, this report reveals how metal 3D printing is transforming industries and pushing the boundaries of manufacturing.</p><p>Read the intro to the report <a href="https://www.wevolver.com/article/metal-3d-printing-technology-report">here</a> and an excerpt from chapter 3 below.&nbsp;</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMzODI4MDc1ODA0LTUgUmlzaW5nIFRyZW5kcyBmb3IgQUkgQWRvcHRpb24gaW4gTWFudWZhY3R1cmluZyAoMTkyMCB4IDUwMCBweCkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe id="JotFormIFrame-243032488553458" title="Metal 3D Printing Report" allowtransparency="true" src="https://form.jotform.com/243032488553458" frameborder="0" style="min-width: 100%; max-width: 100%; height: 630px; border: none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span> </iframe></span></p><p dir="ltr" id="isPasted">Metal additive manufacturing generally requires extensive post-processing to achieve fully dense, usable parts. Processes that deposit metal mixed with a binder matrix (binder jetting, extrusion) are the most dependent on post-processing to achieve desired part characteristics, since the as-printed (green) parts are not fully metal. However, all processes, including powder bed fusion and DED, require some degree of post-processing.</p><p dir="ltr">In this chapter, we separate metal AM post-processing into four categories: debinding and sintering, CNC machining and milling, heat treatment, and quality assurance. (Another essential process, support removal, is not included due to its relative simplicity.) The first three of the three categories are concerned with the physical alteration of the printed parts to bring about the desired shape or material characteristics, while quality assurance is concerned with inspection. Metal 3D printing workflows may use any combination of the described post-processing techniques or other workflow-specific techniques not mentioned here.</p><h3 dir="ltr">Debinding and sintering</h3><p dir="ltr">Printed metal parts made using binder jetting or material extrusion consist of both metal and a sacrificial binder material, so the binder must be removed to create a true metal part (as with metal injection molding (MIM)) before sintering to strengthen and densify the part. Exceptions include HP’s Metal Jet binder jetting technology, whose binder decomposes during sintering and which therefore does not require debinding. Sintering results in a degree of (anisotropic) part shrinkage, which must be factored into part design.</p><p dir="ltr" id="isPasted">Binder is removed from metal parts using catalytic, solvent, thermal debinding, or a combination of the three. The appropriate method generally depends on the material and its binder.</p><div dir="ltr" align="left"><table><tbody><tr><td><p dir="ltr">Process</p></td><td><p dir="ltr">Description</p></td><td><p dir="ltr">Advantages</p></td><td><p dir="ltr">Disadvantages</p></td></tr><tr><td><p dir="ltr">Catalytic debinding</p></td><td><p dir="ltr">Uses catalytic acid vapor, typically 98.5% nitric acid gas, to turn binder into vapor that can be blown away</p></td><td><p dir="ltr">Fastest method</p></td><td><p dir="ltr">Environmental and safety risks</p></td></tr><tr><td><p dir="ltr">Solvent debinding</p></td><td><p dir="ltr">Uses liquid organic solvents like hexane to remove binder</p></td><td><p dir="ltr">Fast method</p></td><td><p dir="ltr">Requires complex preparation and planning</p></td></tr><tr><td><p dir="ltr">Thermal debinding</p></td><td><p dir="ltr">Uses furnace to slowly soften binder and enable its removal</p></td><td><p dir="ltr">Simplest and safest method</p></td><td><p dir="ltr">Slow and can introduce stresses to metal</p></td></tr></tbody></table></div><p dir="ltr">A key advantage of thermal debinding is that the same furnace can be used for debinding and sintering. A lower temperature is used for debinding (usually under 500°C) before a higher temperature is introduced for sintering (usually above 1000°C). Several 3D printer manufacturers supply debinding and sintering furnaces that can be used for post-processing of metal parts. Another advantage of thermal debinding is that furnaces can be brought in-house with relative ease. By contrast, parts that require catalytic debinding (those produced using BASF Ultrafuse filament, for example) may need to be shipped to a third-party debinding specialist.</p><p dir="ltr">Debinding and sintering equipment producers include:</p><ul><li dir="ltr"><p dir="ltr">Desktop Metal: Introduced its PureSinter high-purity vacuum in 2024, which is capable of sintering titanium to 98% density. Compatible with binder jetting, material extrusion, and traditional techniques like MIM.</p></li><li dir="ltr"><p dir="ltr">Markforged: Supplies the Wash 1 solvent debinding station (along with a separate sintering furnace) for use with its Metal X 3D printer. Uses Opteon SF-79 solvent.</p></li><li dir="ltr"><p dir="ltr">The Virtual Foundry: Wisconsin company supplying Filamet metal filament and sintering kilns (Virtual Foundry, FireX, FireX Max) with temperatures up to 1288°C.</p></li></ul><h3 dir="ltr">Heat treatment</h3><p dir="ltr">The rapid heating and cooling of metal additive manufacturing processes produce “heterogeneous microstructures and the accumulation of internal stresses,” the effect of which can be reduced via heat treatment. Heat treatment can remove internal stresses and improve hardness and fatigue strength. Without heat treatment, 3D printed metal parts are significantly outperformed by traditionally made (machined, cast, forged) equivalents. Heat treatment can be applied to parts made using a variety of technologies, including LPBF, DED, and binder jetting.</p><p dir="ltr">Different heat treatment processes may suit different metals. Some of the major heat treatment processes for 3D printed metal parts are outlined in the table below. Other processes like annealing, normalizing, and precipitating hardening may also be used on certain metals.</p><div dir="ltr" align="left"><table><tbody><tr><td><p dir="ltr">Process</p></td><td><p dir="ltr">Description</p></td></tr><tr><td><p dir="ltr">Solution treatment</p></td><td><p dir="ltr">Heating of parts to high temperature followed by rapid cooling</p></td></tr><tr><td><p dir="ltr">Stress relieving</p></td><td><p dir="ltr">Heating of parts followed by controlled cooling to alleviate residual stresses</p></td></tr><tr><td><p dir="ltr">Hot isostatic pressing (HIP)</p></td><td><p dir="ltr">Simultaneous isostatic pressurization and heating of parts to high temperature to densify and remove internal defects</p></td></tr></tbody></table></div><p dir="ltr">A handful of companies specialize in the heat treatment of metal 3D printed parts, providing services or manufacturing hardware such as furnaces and presses. Most companies in this field are established and previously provided heat treatment for conventionally manufactured metal parts.</p><p dir="ltr">Heat treatment companies include:</p><ul><li dir="ltr"><p dir="ltr">Paulo: Missouri-based heat treatment expert founded in 1943. Provides HIP and other services.&nbsp;</p></li><li dir="ltr"><p dir="ltr">Quintus Technologies: High-pressure machine manufacturer based in Sweden. Supplies HIP equipment to Paulo and others.</p></li></ul><h3 dir="ltr">Surface finishing</h3><p dir="ltr">Surface finishing technologies and techniques may be used for post-processing of metal parts produced using any metal additive manufacturing technology. Surface finishing techniques include but are not limited to sanding, abrasive blasting, vibratory finishing, dry electropolishing, and CNC machining.</p><ul><li dir="ltr"><p dir="ltr">Sanding: Metal 3D printed parts may be subject to manual or automated sanding to remove surface imperfections. For parts produced using binder jetting or material extrusion, sanding the green part prior to debinding and sintering can increase surface quality.</p></li><li dir="ltr"><p dir="ltr">Blasting: Abrasive media blasting is another common post-processing technique for parts produced using LPBF and other technologies. Advantages of media blasting include speed and minimal impact on part dimensions. Media may include glass beads or alumina.</p></li><li dir="ltr"><p dir="ltr">Vibratory finishing: Tumbling is used to smooth the surface of metal parts and increase hardness. It requires less manual supervision than media blasting and can produce equivalent or better results. Chemically accelerated vibratory surface finishing or superfinishing is a related low-cost process in which a chemical solution is used to coat the metal, helping to remove peaks while maintaining valleys.</p></li><li dir="ltr"><p dir="ltr">Dry electropolishing: The patented DryLyte process from DLyte uses an electrical flow to create an ion exchange that removes material only from roughness peaks, keeping edges intact and accessing hard-to-reach corners.</p></li><li dir="ltr"><p dir="ltr">Machining:&nbsp;CNC machining can be used to turn near-net-shape parts into final parts, achieve tighter tolerances on critical features, improve dimensional accuracy, and produce the desired surface finish. Suitable machines include 3-axis, 4-axis, and 5-axis machining (milling) centers, as well as electrical discharge machining (EDM) centers.</p></li></ul><h3 dir="ltr">Quality assurance</h3><p dir="ltr">Quality assurance is an important area of post-processing for metal parts, particularly end-use or production parts in fields like aerospace, as parts must meet regulatory standards set by relevant industrial bodies. Traditional equipment like coordinate measurement machines (CMMs) may be used to assess dimensional accuracy, while internal inspection using CT scanners and other equipment is especially important as the microstructure and porosity of printed metal parts can vary. Automated quality assurance solutions are becoming more common as manufacturers look to make additive manufacturing as efficient as possible on the production line.</p><p dir="ltr">Key quality assurance processes for metal 3D printing include part measurement using CMMs and non-destructive testing methods like computed tomography (CT), ultrasonic testing, and conductivity testing, which are critical for analyzing the internal structure of printed parts. Other quality assurance processes that are not technically part of the post-processing stage include in-process monitoring, material selection and testing, and statistical process control.</p><blockquote><p dir="ltr">“One of the big advantages of designing for metal AM is topology optimization, which allows you to take advantage of minimalist designs and minimal material usage to create the strongest and lightest parts. But you often run into these organic shapes and designs that are very difficult to inspect,” explains Matt Schmidt, Senior Solutions Engineer at Xometry. “How do we know that we have accomplished everything in that print to match the performance that we dictated during the optimization process? For that, 3D scanning becomes very critical, as does high-resolution CMM for evaluating the tolerances of 3D prints. CT and x-ray scans are also very important to study part microstructure and detect any porosity, voids or gaps in parts that could result in potential failures.”</p></blockquote><p dir="ltr">Companies providing quality assurance solutions include:</p><ul><li dir="ltr"><p dir="ltr">QC Labs: Non-destructive testing service provider to additive manufacturing and CNC machining users. Uses various technologies including CT scanning, ultrasonic testing, and digital radiography.</p></li></ul><p>Theta Technologies: UK company specializing in non-destructive testing equipment. Its systems use nonlinear resonance technology to detect internal flaws in metal parts.</p><hr><p id="isPasted"><a href="https://www.wevolver.com/article/metal-3d-printing-technology-report"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733839566614-1733839566614.png" class="fr-fic fr-dii"></a></p><p><br></p><p><a href="https://www.wevolver.com/article/chapter-1-core-metal-3d-printing-technologies"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733839566622-1733839566622.png" class="fr-fic fr-dii"></a></p><p><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-1-core-metal-3d-printing-technologies"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733839566628-1733839566628.png" class="fr-fic fr-dii"></a></p><p><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-3-post-processing-for-metal-am"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733839566634-1733839566634.png" class="fr-fic fr-dii"></a></p><p><br></p><p>Get the full report immediatley by downloading below.&nbsp;</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMzODI4MTk4MzMwLURPV05MT0FEIEJFTE9XLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable fr-active"><iframe id="JotFormIFrame-243032488553458" title="Metal 3D Printing Report" allowtransparency="true" src="https://form.jotform.com/243032488553458" frameborder="0" style="min-width: 100%; max-width: 100%; height: 630px; border: none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span> </iframe></span></p><p><br></p>

In this chapter, we separate metal AM post-processing into four categories: debinding and sintering, CNC machining and milling, heat treatment, and quality assurance. 

The Metal 3D Printing Technology Report: Chapter 3: Post-processing for Metal AM

<p dir="ltr" id="isPasted">An FDM 3D printer is a great tool for making all manner of parts and products. The technology is particularly notable for its ability to create hollow or complex geometries on demand. However, the geometry and design of a print is only part of the equation, materials are a major consideration when planning a 3D printing project. The choice of 3D printing filament will influence all sorts of factors, including the cost of a project, the appearance of a print, and, most importantly, the mechanical properties of the final part. For example, if you are looking to make a flexible object, such as a wearable or gasket, it is imperative that you work with a filament that has flexible properties.</p><p dir="ltr">Polylactic acid (PLA), while the most commonly used filament today, is not known for its flexibility. In fact, the material is highly rigid and in some cases even brittle. This means that it can fracture when stressed, with little deformation before breaking. In this article, we’ll be diving deeper into PLA’s properties to understand if it can be more flexible. We’ll also be looking at flexible filaments that can be used as an alternative to PLA when flexibility is needed.</p><h2 dir="ltr">PLA filament properties&nbsp;</h2><p dir="ltr">Neat PLA filament is a rigid thermoplastic known for its easy printability and high strength. Despite a tensile strength of around 50 MPa (<a href="https://www.wevolver.com/article/comparison-of-pla-abs-and-petg-filaments-for-3d-printing" target="_blank">ABS, for comparison has a tensile strength of about 30 MPa</a>), PLA is rigid, offering little flexibility and can actually become more brittle if subjected to stress over time or under extreme conditions. To put that into perspective, PLA has among the lowest elongation at break measurements of the common 3D printing filaments.&nbsp;</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733489740277-3d_printed_objects_on_table.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="PLA 3D prints in different colors"><span class="fr-inner">PLA is the most commonly used 3D printing filament, though it is not known for its flexibility.</span></span></span></p><p dir="ltr">What is elongation at break? Elongation at break is a material property that refers to the ability of a material to stretch or elongate before it breaks or fractures. It is typically expressed as a percentage of the material's original length and is a measure of ductility or plasticity. In a standard tensile test, a sample of the material is pulled in tension until it breaks. The elongation at break is calculated by measuring the change in length of the sample and dividing it by the original length, then multiplying by 100.</p><p dir="ltr">Of course, the specific elongation at break measurement varies depending on the brand of filament used, print settings such as infill and print speed, and geometry of the 3D print.[2] Generally speaking, however, this is how the most common 3D printing filaments compare when it comes to flexibility:</p><div dir="ltr" align="left"><table><tbody><tr><td><p dir="ltr"><strong>3D Printing Filament</strong></p></td><td><p dir="ltr"><strong>Elongation at Break (%)</strong></p></td></tr><tr><td><p dir="ltr">PLA</p></td><td><p dir="ltr">1-6%</p></td></tr><tr><td><p dir="ltr">ABS</p></td><td><p dir="ltr">20%</p></td></tr><tr><td><p dir="ltr">PETG</p></td><td><p dir="ltr">15-30%</p></td></tr><tr><td><p dir="ltr">TPU</p></td><td><p dir="ltr">300–700%</p></td></tr></tbody></table></div><p dir="ltr">Another key property of <a href="https://www.wevolver.com/article/pla-bed-temperature" target="_blank">PLA is its low melting point</a> and glass transition temperature. This means that the material is easy to process on a desktop FDM 3D printer, since it does not necessarily require a heated print bed or high nozzle temperatures (PLA prints best between 200-220 °C). However, the polymer’s low glass transition temperature of 60 °C also means that printed PLA components cannot be used in applications that require heat resistance.&nbsp;</p><p dir="ltr"><strong>Recommended reading:<a href="https://www.wevolver.com/article/is-pla-food-safe" target="_blank">&nbsp;Food-grade 3D printing: Is PLA Food-Safe?</a></strong></p><h2 dir="ltr">PLA+, Flexible PLA, and Soft PLA</h2><p dir="ltr">As we’ve seen, neat PLA is not known for its flexibility, however there are some PLA 3D printing products that have been engineered for increased flexibility through the use of special additives. For example, PLA+ (or PLA Plus) is an enhanced version of PLA that integrates plasticizers and toughening agents for better impact resistance and some degree of flexibility. Generally, PLA+ is not highly flexible, but it is somewhat more flexible than standard PLA. It is also designed to be tougher, more impact-resistant, and less prone to breaking under stress. For applications where true flexibility is required, however, PLA+ is still limited. For example, eSun’s PLA+ 3D printing material has an elongation at break of 20%, comparable to ABS.</p><p dir="ltr">Flexible PLA is a variation of PLA mixed with flexible materials, such as thermoplastic elastomers (TPE) or thermoplastic polyurethane (TPU). It retains the ease of use associated with PLA, offering low printing temperatures and reduced warping. Flexible PLA filament can stretch and return to its original shape, making it suitable for gaskets, wristbands, and protective covers or phone cases. While it’s easier to print than highly flexible filaments like TPU or TPE, it is still more rigid than those materials.</p><p dir="ltr">Soft PLA is another type of filament that typically combines PLA with other additives to improve elasticity and bendability, making it ideal for items like soft toys, flexible parts, or protective covers. However, "soft" in this context doesn't mean highly flexible—the material is still relatively rigid compared to true flexible filaments. It’s worth noting that while Soft PLA is more flexible than neat PLA, the material does not have the same elasticity as elastomers such as TPU.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/tpu-vs-pla" target="_blank">TPU vs PLA: Choosing Between Flexible and Rigid Filament for 3D Printing</a></strong></p><h2 dir="ltr">Flexible alternatives to PLA filament</h2><p dir="ltr">For applications that require a high degree of elasticity, such as footwear, orthopedic models, tubes, seals, and more, there are elastomer filaments like TPU and TPE to consider.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733489800010-3d_printer_creating_object+%281%29.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="3D printing footwear flexible filament"><span class="fr-inner">Flexible filaments are useful for 3D printing wearables, such as footwear.</span></span></span></p><h3 dir="ltr">TPU and TPE Filaments</h3><p dir="ltr">TPU (thermoplastic polyurethane) is a highly flexible, rubber-like 3D printing filament known for its elasticity, strength, and abrasion resistance. It is a type of thermoplastic elastomer (TPE), meaning it combines the flexibility of rubber with the processing ease of a polymer. TPU can stretch significantly and return to its original shape, making it ideal for parts that require high durability, impact resistance, and flexibility.</p><p dir="ltr"><strong>Key Features of TPU:</strong></p><ul><li dir="ltr"><p dir="ltr">Flexibility &amp; Elasticity: TPU can stretch in the range of 600% of its original length without breaking, making it perfect for flexible and elastic parts like phone cases, shoe soles, gaskets, and bumpers.</p></li><li dir="ltr"><p dir="ltr">Durability: TPU is highly abrasion-resistant, tear-resistant, and impact-resistant, which gives it a long lifespan even in harsh conditions.</p></li><li dir="ltr"><p dir="ltr">Chemical Resistance: It also has good resistance to oils, greases, and various chemicals.</p></li></ul><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/what-is-tpu-material-in-3d-printing-material-properties-applications-and-technologies" target="_blank">What is TPU Material in 3D printing: material properties, applications, and technologies</a></strong></p><p dir="ltr">TPE (thermoplastic elastomer) is a flexible 3D printing filament that combines the elasticity and rubber-like properties of traditional elastomers with the processability of thermoplastics. Like TPU (a similar material), TPE is designed to provide high flexibility, stretchability, and reliability in applications requiring soft, bendable parts.</p><p dir="ltr"><strong>Key Features of TPE:</strong></p><ul><li dir="ltr"><p dir="ltr">Flexibility and Softness: TPE can stretch significantly, offering rubber-like elasticity. It is commonly used to print parts like soft toys, wearables, gaskets, flexible hinges, and grips.</p></li><li dir="ltr"><p dir="ltr">Durability: TPE is abrasion-resistant, impact-resistant, and has excellent fatigue resistance, making it suitable for items that endure frequent bending or compression.</p></li><li dir="ltr"><p dir="ltr">Chemical Resistance: TPE is resistant to oils, greases, and various chemicals, offering good durability in environments where such substances are present.</p></li></ul><p dir="ltr">The main drawbacks of using elastic 3D printing filaments is that they are a) more expensive than PLA spools and b) they are more challenging to 3D print. Specifically, TPU and TPE’s elasticity can cause issues like <a href="https://www.wevolver.com/article/3d-printer-stringing" target="_blank">stringing</a>, <a href="https://www.wevolver.com/article/how-to-clean-3d-printer-nozzle" target="_blank">clogs, or jamming</a>, especially with Bowden extruders, which struggle to push flexible filament through the tube. Direct-drive extruders are therefore recommended for smoother printing. Flexible filaments also require slower print speeds (typically 20-30 mm/s) and lower <a href="https://www.wevolver.com/article/cura-retraction-settings" target="_blank">retraction settings</a> to avoid extrusion problems. Additionally, TPU and TPE print at higher temperatures compared to PLA. TPE and TPU also come with more limited post-processing options that more rigid filaments.</p><p dir="ltr">Ultimately, while PLA is user-friendly and forgiving, TPU demands more careful settings and attention during printing for optimal results. Below are some 3D printing tips for flexible filaments:</p><p dir="ltr"><strong>3D Printing with TPU:</strong></p><ul><li dir="ltr"><p dir="ltr">Print Settings: TPU requires slower print speeds (typically around 20-30 mm/s) to prevent issues like stringing or clogging. It also requires lower retraction settings due to its flexibility.</p></li><li dir="ltr"><p dir="ltr">Print Temperature: TPU filament prints best at 224–250 °C.</p></li><li dir="ltr"><p dir="ltr">Extruder Compatibility: Direct-drive extruders are generally recommended for TPU, as Bowden setups may struggle with the filament’s flexibility.[1]</p></li></ul><h3 dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733489815675-man_using_3d_printer.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="Man troubleshooting 3D printer"><span class="fr-inner">TPE and TPU can be tricky to 3D print and makers should be aware of problems like stringing and nozzle clogs.</span></span></span></h3><h3 dir="ltr">Polypropylene (PP)</h3><p dir="ltr">Polypropylene (PP) filament is flexible, but it has a distinct set of characteristics compared to other flexible filaments like TPU or TPE. Polypropylene is a lightweight, durable, and flexible thermoplastic known for its high impact resistance, chemical resistance, and fatigue resistance. It can bend and stretch without cracking, making it ideal for applications like hinges, living hinges, containers, and flexible parts that need to withstand repeated stress.</p><p dir="ltr">In tests, PP filament has demonstrated an elongation at break in the range of &gt;800% and an elongation at yield in the range of 35%.[3] It also tends to be more challenging to print due to its low surface adhesion and tendency to warp. PP generally requires a heated bed (around 100-110°C) and sometimes a heated chamber for optimal results.&nbsp;</p><h2 dir="ltr">Conclusion</h2><p dir="ltr">In the end, while PLA is a popular and easy-to-use filament, it is not particularly flexible and can become brittle under stress. For applications requiring flexibility, alternatives like PLA+, Flexible PLA, and Soft PLA offer some improved flexibility, though they are still not as elastic as elastomeric materials. TPU and TPE are a suitable option for applications that require flexibility, such as phone cases, gaskets, or wearables. However, they come with their own set of challenges, including difficult printing conditions, higher temperatures, and more intricate print settings. Materials like Polypropylene (PP) offer flexibility with high impact and chemical resistance but can also be tricky to print. Ultimately, the choice of filament depends on the specific requirements of the project, including flexibility, durability, and ease of printing. For maximum flexibility and durability, TPU and TPE are recommended, but users should be prepared for a steeper learning curve compared to PLA.</p><h2 dir="ltr">Frequently Asked Questions (FAQs)</h2><h4 dir="ltr">Q: Is PLA flexible?</h4><p dir="ltr">A: No, PLA is a rigid filament and is not known for its flexibility. It is brittle and can break under stress with little deformation. It has a low elongation at break (1-6%), meaning it doesn’t stretch much before snapping.</p><h4 dir="ltr">Q: What is PLA+ and how flexible is it?</h4><p dir="ltr">A: PLA+ (or PLA Plus) is an enhanced version of PLA that incorporates toughening agents and plasticizers for better impact resistance and some flexibility. PLA+ has an elongation at break of around 20%, making it tougher and more resilient than standard PLA but still not highly flexible.</p><h4 dir="ltr">Q: What is Flexible PLA?</h4><p dir="ltr">A: Flexible PLA is a blend of PLA mixed with elastomers like TPU or TPE, making it more flexible than regular PLA. It is suitable for items like gaskets and phone cases. However, it is still more rigid than true flexible filaments and lacks the stretchability of materials like TPU or TPE.</p><p dir="ltr"><strong>Q: What are the challenges of 3D printing with TPU and TPE?</strong></p><p dir="ltr">A: TPU and TPE filaments are more challenging to print compared to PLA due to their flexibility, which can cause issues like stringing, clogs, and jamming, especially with Bowden extruders. These filaments require slower print speeds (around 20-30 mm/s) and lower retraction settings to avoid extrusion problems. Additionally, TPU and TPE require higher print temperatures and are less forgiving during the post-processing stage compared to rigid filaments like PLA.</p><h2 dir="ltr">References</h2><p dir="ltr">[1] Flexible Materials Guide [Internet]. Simplify3D, 2024. Available from: <a href="https://www.simplify3d.com/resources/materials-guide/flexible/" target="_blank">https://www.simplify3d.com/resources/materials-guide/flexible/</a>&nbsp;</p><p dir="ltr">[2] Leite M, Fernandes J, Deus AM, Reis L, Vaz MF. Study of the influence of 3D printing parameters on the mechanical properties of PLA.</p><p dir="ltr">[3] Ultimaker PP Technical data sheet [Internet]. UltiMaker, April 20, 2022. Available from: <a href="https://um-support-files.ultimaker.com/materials/2.85mm/tds/PP/Ultimaker-PP-TDS-v3.00.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">https://um-support-files.ultimaker.com/materials/2.85mm/tds/PP/Ultimaker-PP-TDS-v3.00.pdf</a>&nbsp;</p>

The most commonly used 3D printing filament, PLA is not known for its flexibility. We explore why that is and list some alternative 3D printing materials can be used when flexibility is needed.

Flexible 3D printer filaments: is PLA flexible?

<p>Digital light synthesis (DLS) is the signature technology of digital manufacturing company <a rel="noopener noreferrer" href="https://www.carbon3d.com/" target="_blank" id="isPasted">Carbon</a>. It allows for the rapid 3D printing of plastic parts in production-grade materials. DLS technology uses light to set the 3D shape of printed parts, then parts undergo a thermal-curing process that brings them to their final material properties. By combining these processes, Carbon’s additive manufacturing technology is able to blend the speed and design freedom of light-curing 3D printing processes with superior plastic material properties typically not possible with 3D printing.</p><h3 id="isPasted">Designing for Carbon’s 3D Printing Technology</h3><p>Many of the same tactics used to mitigate warping in&nbsp;<a href="https://www.protolabs.com/en-gb/services/injection-moulding/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-1224&utm_content=wevolver-carbon-3dp-1224" title="Injection Molding" target="_blank" rel="noopener noreferrer">injection moulding</a> apply to 3D printing as well. Maintaining uniform wall thicknesses, adding radii to interior corners, and building support ribs all help with the dimensional stability of Carbon parts and lessen part warpage.</p><p>Carbon’s technology excels at lattice-type geometries, but struggles with large cross sections caused by bulky, thick parts. Avoid thick walls and ideally stay under 2.54mm wall thickness. Try hollowing parts, adding lattices or honeycombs, or adding holes to remove material unnecessary to the functionality of the part.</p><p>Surfaces 45 degrees and steeper from the draw plane typically do not require supports. Marching walls up and over at 45 degrees instead of hard 90-degree angles will typically make a part build more accurately and require less supports. Once again, adding a radius to internal and external corners often mitigates or even removes the need for supports on many parts.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733222222556-image+cw.jpg" style="width: 544px;" class="fr-fic fr-dib"></p><p><em>Build platform (1), UV curable resin (2), dead zone (3), oxygen permeable window (4), projector (5).</em></p><p><em>Along these lines, here are important size and design considerations when using Carbon:</em></p><p><em><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733222328102-1733222328102.png" style="width: 692px;" class="fr-fic fr-dib"></em></p><h3 id="isPasted">Carbon DLS vs. Stereolithography</h3><p>Carbon’s technology is a “vat photopolymerisation” 3D printing process, which places it in the same technology family as <a href="https://www.protolabs.com/en-gb/services/3d-printing/stereolithography/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-1224&utm_content=wevolver-carbon-3dp-1224" title="Stereolithography" target="_blank" rel="noopener noreferrer">stereolithography (SLA)</a>. Fundamentally, this means it builds parts by curing liquid photopolymers into a solid by selectively exposing them to light. That said, Carbon differs from SLA in a number of ways:</p><ul><li>Carbon emits light via a digital light projection (DLP) chip similar to how a projector casts an image on a screen. This is in contrast to how SLA draws features, which is at a single point of space at a time with a laser. The implications of this are that Carbon can print much faster (just as you can stamp an image faster than you can draw it) but this does come with a trade-off for accuracy and surface finish.</li><li>Carbon technology essentially builds “upside down” in relation to conventional SLA. To facilitate this, Carbon emits the light used for curing through a clear pane at the bottom of the resin vat. Once again, this is a trade-off. Building this way allows Carbon to build faster but it also requires stronger supports.</li><li>There are other systems that print parts “upside down” like Carbon, but Carbon has a unique twist in that the pane the light passes through is also oxygen permeable. This is important because the liquid photopolymer will not cure into a solid if it is saturated with oxygen. Normally systems like this need to physically pull the parts off this pane as they are effectively glued to each layer, but Carbon is able to do so without being so rough on the parts. The oxygen prevents the resin immediately off the glass from curing, allowing the part to raise off without having to physically rip from the pane on every layer. This enhancement not only significantly improves the print speed but also reduces the supports required.</li><li>Historically, vat photopolymerisation materials were not known for their durability nor longevity. Since the technology fundamentally creates parts with light, the materials were naturally light-sensitive. Parts made via SLA are typically sensitive enough to UV light that they may discolour in just a few hours of exposure to sunlight. However, Carbon found a singular solution to this problem. The technology’s unique resins combine aspects of not just photopolymers but also two-part urethanes. This means Carbon parts require a thermal cycle after they are built to reach their final properties, but makes them much more durable.</li><li>Finally, in terms of usage, Carbon parts can be used for both functional prototypes and end-use production parts. Typically SLA parts are cheaper and more accurate for rapid prototyping, but Carbon offers additional material properties that SLA does not. Carbon materials are much more durable, UV resistant, and chemical resistant than SLA materials. If the prototypes see demanding environments, then Carbon may be the best option.</li></ul><h3>Carbon DLS vs. Multi Jet Fusion</h3><p>Both Carbon and&nbsp;Multi Jet Fusion&nbsp;(MJF) are well suited for functional prototypes and low-volume production, so when should you use one or the other? Here are some elements to consider:</p><p><strong>Materials.</strong> The materials offered by the two technologies are quite different. &nbsp;MJF prints parts in nylon 11, 12 and TPU. These nylon materials are both moderately stiff and flexible, and have impressive impact resistance. At Protolabs, we offer four Carbon materials— including rigid polyurethane and flexible polyurethane. The rigid polyurethane is similar to MJF’s material in stiffness, but offers superior flexibility. The flexible polyurethane is less stiff but offers tremendous flexibility and is similar to moulded polypropylene in its material properties.&nbsp;</p><p><strong>Holes, slots, channels.</strong> Though the minimum feature size of both technologies is similar (at about 0.5mm), Carbon is much better at forming “negative spaces” like holes, slots, and channels. This is because of the powder used in MJF, and the media is difficult or impossible to remove from small gaps. If the part design has several holes or complex channels, it is likely a better fit for Carbon.</p><p><strong>Part size.</strong> At Protolabs factory, Carbon can produce larger parts than MJF. If the part is larger than 284 mm x 380 mm x 380 mm it may be necessary to print it via DLS because it may be too large for the MJF platform, alternatively our network may be able to support.</p><h3>Applications for Carbon DLP 3D Printing Technology</h3><p>Carbon is one of the best technologies available for 3D printing plastic parts for low-volume production. Non-bulky parts with moderate-to-high complexity are typically good candidates for this technology. Though critical features can be “dialled-in” for improved tolerances, Carbon has looser tolerances than injection moulding so the candidate parts should not require overly tight tolerances.</p><p>Carbon is frequently used for intricate designs that are challenging to mould and durable 3D-printed components for end-use applications. Some recent high-profile products that Carbon has produced include its work with <a href="https://www.carbon3d.com/resources/case-study/made-with-carbon-dls" target="_blank" rel="noopener noreferrer">Adidas and its AlphaEdge 4D running shoe</a>, <a href="https://www.carbon3d.com/resources/case-study/made-with-carbon-dls" target="_blank" rel="noopener noreferrer">a Riddell football helmet</a>, <a href="https://www.carbon3d.com/resources/case-study/made-with-carbon-dls" target="_blank" rel="noopener noreferrer">and a high-performance bike saddle for cyclists.</a> Carbon parts also are used regularly in medical and dental industries.</p><p><br></p>

Tips on how to design for Carbon’s additive manufacturing technology, and how Carbon stacks up against stereolithography and Multi Jet Fusion 3D printing.

Create Production Parts with Carbon 3D Printing

<p data-pm-slice="1 1 []" id="isPasted">The design process in metal 3D printing is a blend of creativity, engineering precision, and innovative technology. Unlike traditional manufacturing, where designs are often constrained by the limitations of subtractive methods, metal 3D printing allows for unparalleled freedom in creating complex geometries. One of the most transformative elements in this design process is the integration of lattice structures. These intricate, web-like frameworks can drastically improve the efficiency and performance of a component, leading to significant savings in material, cost, and printing time.</p><p><br></p><p><strong>The Design Process in Metal 3D Printing</strong></p><p>When designing for metal 3D printing, engineers and designers are encouraged to think beyond the constraints of traditional manufacturing. This process begins with conceptualizing the part’s function and determining the best way to achieve its purpose using additive manufacturing techniques. The freedom offered by 3D printing allows for the creation of internal features, complex shapes, and optimized structures that would be impossible or highly impractical to produce using conventional methods.</p><p>This is where lattice structures come into play. By integrating these lightweight, yet strong, frameworks into the design, engineers can enhance a component’s performance while simultaneously reducing the amount of material used.</p><p></p><p></p><p><br></p><p><strong>Benefits of Integrating Lattice Structures</strong></p><ol><li data-list-indent="1" data-list-type="bulleted"><p><strong>Material Savings</strong>: One of the most significant advantages of using lattice structures is the reduction in material usage. By replacing solid sections of a component with a lattice framework, the overall volume of material required is greatly decreased. This not only lowers the cost of raw materials but also reduces the weight of the component, which can be particularly beneficial in industries such as aerospace and automotive where every gram counts.</p></li><li data-list-indent="1" data-list-type="bulleted"><p><strong>Cost Reduction</strong>: Material savings naturally lead to cost reduction. The fewer raw materials needed, the lower the production cost. Additionally, because lattice structures reduce the overall mass of a part, the time required to print the component is also reduced, leading to further cost savings in terms of machine time and energy consumption.</p></li><li data-list-indent="1" data-list-type="bulleted"><p><strong>Improved Performance</strong>: Lattice structures are not just about saving material—they also enhance the mechanical performance of components. These structures can be designed to distribute stress more evenly, improve energy absorption, and increase the overall strength-to-weight ratio of a part. This makes them ideal for components that need to withstand high loads or impacts while maintaining a low weight.</p></li></ol><p><br></p><p><strong>Easy Integration with Autodesk Lattice Tools</strong></p><p>Integrating lattice structures into component designs has never been easier, thanks to advanced design tools like Autodesk’s lattice generation features.<a href="https://www.autodesk.com/asean/products" target="_blank" rel="noopener noreferrer"> Autodesk</a> software, such as Fusion 360, offers intuitive tools that allow designers to easily incorporate lattice structures into their 3D models. These tools enable the automatic generation of lattices based on the desired density, cell shape, and mechanical properties, ensuring that the final design is optimized for both performance and manufacturability.</p><p>With Autodesk’s lattice tools, designers can quickly explore different lattice configurations, simulate their performance, and make adjustments as needed before finalizing the design for printing. This seamless integration of lattice structures into the design process not only speeds up development but also ensures that the final component is both efficient and effective.</p><p><br></p><p><strong>Conclusion: Lattice Structures as a Design Revolution</strong></p><p>The integration of lattice structures in metal 3D printing represents a significant advancement in the way components are designed and manufactured. By leveraging the benefits of reduced material usage, lower costs, and enhanced performance, designers can create optimized parts that meet the highest standards of efficiency and functionality. Tools like Autodesk’s lattice generation features make it easier than ever to incorporate these structures into designs, paving the way for more innovative and cost-effective solutions in a wide range of industries. As metal 3D printing continues to evolve, the use of lattice structures will undoubtedly play a central role in pushing the boundaries of what is possible in component design.</p>

Integrating lattices in the component design

One of the most transformative elements in the design process for metal 3D printed parts is the integration of lattice structures as these can drastically improve the efficiency and performance of a component.

Optimizing Component Design with Lattice Structures in Metal 3D Printing

<p id="isPasted">As global supply chains face increasing pressure and manufacturing demands grow more complex, 3D printing is moving to the forefront of the additive manufacturing space as a cost-efficient, reliable and flexible tool that is changing how people and companies view workflow optimization and production uptimes.</p><p>One of the key areas where&nbsp;<a href="https://ultimaker.com/">UltiMaker’s 3D printing solutions</a> are being leveraged is in manufacturing components with complex geometries(including lattices or internal channels), small production runs and various tooling, jigs, and fixtures used to improve existing traditional manufacturing workflows. Let’s dive into some of the key benefits that 3D printing provides and go over some application examples:</p><h2>Reducing material waste</h2><p>When compared to traditional subtractive manufacturing methods such as milling or CNC routing, which will always result in wasted material as part of the part-shaping process, 3D printers will only use as much material as needed for the part, layer by layer. This is further compounded when taking into consideration complex assemblies that often require The ability to produce parts as needed translates directly into reduced costs associated with maintaining large inventories.</p><h2>Accelerated prototyping and iterations</h2><p>UltiMaker allows companies to exponentially increase the speed with which they can prototype, test, and refine designs. This is done without needing to rely on expensive external suppliers, which, as we’ve seen in recent years, are vulnerable to supply chain delays or interruptions.</p><p>Global brands such as <a href="https://ultimaker.com/learn/heineken-ensuring-production-continuity-with-3d-printing/">Heineken have ensured production continuity with 3D printing</a> and decreased lead times (by as much as nine months) and production costs by 3D printing spare parts for their packaging and assembly machinery.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733216290885-1733216290885.png" class="fr-fic fr-dib"></p><h2 id="isPasted">Eliminating tooling costs</h2><p>Traditional manufacturing methods often require expensive molds, dies, or tooling for each part design and more and more manufacturers are turning to 3D printing technologies to create mold inserts, assembly aids and jigs in order to streamline their production. With a market value estimated at over $73.60 billion the tooling application area is one of the fastest growing: whereas only 37% of manufacturers reported using additive manufacturing for tooling in 2019 that number grew to 57% in 2021.</p><p>UltiMaker 3D printers allowed companies like <a href="https://ultimaker.com/learn/volkswagen-autoeuropa-maximizing-production-efficiency-with-3d-printed-tools-jigs-and-fixtures/">Volkswagen Autoeuropa to produce tools and fixtures in-house</a> and within two years see assembly-tooling cost savings increased from 70% to 95% (saving an estimated $375,000 per year).</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733216309556-3d-printed-wheel-protection-jig.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p>In fact, the ability to tune in and dynamically address the needs of operators working on production lines by creating various custom jigs and fixtures allows companies to streamline processes, enhance precision, and reduce the risk of human error. With more and more customer success stories such as Audi Sport’s implementation of UltiMaker’s 3D printing technology to<a href="https://ultimaker.com/learn/audi-sport-3d-printed-tools-jigs-and-fixtures-in-a-day-instead-of-weeks/" id="isPasted">&nbsp;create almost 200 new tools, jigs and fixtures</a> or <a href="https://ultimaker.com/learn/eriks-leveraging-3d-printing-to-improve-manufacturing-processes/">ERIKS’s improvement to their manufacturing process</a>, it’s evident that additive manufacturing is one of the key investments for businesses that want to stay ahead of the curve.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733216327298-1733216327298.png" class="fr-fic fr-dib"></p><h2 id="isPasted">On-demand manufacturing</h2><p>UltiMaker's accessible ecosystem enables distributed manufacturing for custom or low-volume parts. Businesses print just-in-time components instead of mass-producing and storing potentially unused inventory and with over 200+ materials available on our&nbsp;<a href="https://marketplace.ultimaker.com/app/cura/materials">UltiMaker Marketplace</a> we’re already seeing costly metal parts like conveyor infeed worms being replaced.</p><p>This is especially relevant when taking into consideration situations where certain machine parts can no longer be sourced as 3D printing allows manufacturers to reverse engineer obsolete parts and far extend the lifespan of existing legacy systems. Just ask one of our clients Trivium, who turned to 3D printing replacement parts for their automated packaging lines.</p><p>If possible insert an image with the infeed worm that Trivium 3D printed or maybe grab a still from the video with the part being used in the production line?</p><h2>Easy to implement, easy to scale</h2><p>Leveraging 3D printing in production processes is also incredibly easy especially when compared to traditional manufacturing techniques that require experienced engineers and designers to create and operate the complex tooling involved which often comes with complicated specialized software that not only adds to the cost but technical expertise as well.</p><p>With UltiMaker the design process is easily accessible through the various CAD softwares available (with some versions having a reduced learning curve) with the chief advantage being the ability to directly translate a CAD design into a 3D printed prototype faster than with any of the traditional methods currently available.</p><p>Coupled with an unparalleled scaling capability through distributed manufacturing, a single engineer can upload 3D parts in Digital Factory making it available in any of the connected locations for localized production as the operation of the 3D printer itself is extremely simple.</p><h2>The future of manufacturing</h2><p>From rapid prototyping to on-demand production, 3D printing is reshaping the way manufacturers innovate, save costs, decrease lead times, maintain production uptimes, and minimize waste. If you’re looking to leverage the unique benefits of 3D printing, the Ultimaker Factor 4 printer combines state-of-the-art features with unmatched reliability, empowering your business to achieve more with less.</p>

As global supply chains face increasing pressure and manufacturing demands grow more complex, 3D printing is moving to the forefront of additive manufacturing as a cost-efficient, reliable, and flexible tool that is changing how companies view workflow optimization and production uptimes.

Benefits of 3D Printing in Manufacturing

<p dir="ltr" id="isPasted">Thermoplastic Polyurethane (TPU) has become a favorite material for hobbyists and professionals in FDM/FFF 3D printing due to its unique combination of flexibility, durability, and versatility. However, successfully 3D printing with TPU requires a thorough understanding of its thermal properties, including the average TPU glass transition temperature, extrusion temperature, and bed temperature settings. In this article, we’ll explore these factors in-depth, providing the knowledge you need to get the best results with TPU filament.</p><h2 dir="ltr">What is TPU Filament?</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733862510698-3d_printer_extruder_closeup.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="tpu"><span class="fr-inner">TPU filament is the most common flexible material for FDM 3D printing</span></span></span></p><p dir="ltr">TPU, or Thermoplastic Polyurethane, is a versatile elastomer that bridges the gap between flexible rubber and rigid plastics. Known for its flexibility, durability, and abrasion resistance, TPU has become a cornerstone material in 3D printing for applications that require both elasticity and strength. This is partly because other elastomeric materials — rubber and silicone, for example — are not suited to the 3D printing process.[1]</p><p dir="ltr">This thermoplastic material is categorized under flexible filaments, alongside TPE (Thermoplastic Elastomer) and TPA (Thermoplastic Polyamide). TPU stands out due to its balance of mechanical properties, offering a level of rigidity and ease of printing that TPE often lacks. It is highly resistant to wear, chemicals, and environmental factors like UV exposure, making it a reliable choice for both consumer and industrial applications.</p><h3 dir="ltr">TPU Brands and Availability</h3><p dir="ltr">Many reputable filament manufacturers produce TPU, each offering unique formulations tailored for different applications. For example:</p><ul><li dir="ltr"><p dir="ltr"><strong>NinjaFlex</strong>: Known for its superior flexibility and resilience, ideal for wearables and gaskets.</p></li><li dir="ltr"><p dir="ltr"><strong>SainSmart TPU</strong>: Offers a balance of affordability and quality, suitable for hobbyists and professionals alike.</p></li><li dir="ltr"><p dir="ltr"><strong>Fillamentum Flexfill</strong>: Renowned for its consistent diameter and color options, making it a favorite for detailed prints.</p></li></ul><h3 dir="ltr">Beyond Filaments: TPU in Powder Form</h3><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733862520789-industrial_3d_printer.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="pls"><span class="fr-inner">SLS is another 3D printing technology that can be used for TPU parts</span></span></span></p><p dir="ltr">TPU isn’t limited to filament-based printing. It is also available in pellets for injection molding and as a powder for use in Selective Laser Sintering (SLS) printers and other professional additive manufacturing systems.[2] SLS TPU powders enable high-precision, flexible parts with consistent mechanical properties throughout. This makes them ideal for industrial applications, such as producing prototypes, seals, and complex geometries that are difficult to achieve with filament-based methods.</p><p dir="ltr">As the market for TPU expands, newer formulations continue to emerge, offering enhanced features like improved heat resistance, conductivity, or biodegradability, further broadening the scope of what TPU can achieve in 3D printing.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/tpu-vs-pla" target="_blank"><em>TPU vs PLA: Choosing Between Flexible and Rigid Filament for 3D Printing</em></a></strong></p><h2 dir="ltr">Advantages of TPU and Other Flexible Filaments</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733862529656-red_rubber_rings.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="seals"><span class="fr-inner">Seals and gaskets are parts that can be made from TPU</span></span></span></p><p dir="ltr">TPU and other flexible materials provide important advantages in 3D printing. Some are obvious, while some are less well known to beginners.</p><h3 dir="ltr">Flexibility and Elasticity &nbsp;</h3><p dir="ltr">One of TPU’s standout features is its exceptional flexibility, elasticity, and elongation. It can stretch significantly under tension and return to its original shape without permanent deformation, making it perfect for dynamic or load-bearing applications like hinges, gaskets, and flexible connectors. This property also makes TPU ideal for wearable devices and soft robotics, where adaptability and resilience are essential.</p><h3 dir="ltr">Durability &nbsp;</h3><p dir="ltr">TPU is highly durable, offering excellent resistance to wear, tear, and impact. Unlike rigid plastics that may crack or break under stress, TPU absorbs energy and rebounds, significantly enhancing the lifespan of printed parts. This high impact strength is why TPU is often used in protective cases, shoe soles, and automotive components that endure heavy use.</p><h3 dir="ltr">Chemical Resistance &nbsp;</h3><p dir="ltr">Another significant advantage of TPU is its resistance to oils, greases, and various solvents.[3] This chemical resistance makes TPU suitable for industrial applications where exposure to harsh substances is common, such as seals, gaskets, and fluid-handling components.</p><h3 dir="ltr">Versatility &nbsp;</h3><p dir="ltr">TPU is available in various shore hardness levels, allowing users to choose between soft, highly elastic formulations and stiffer, more rigid variants. (Fillamentum, for example, offers TPU with a shore A of 92 or 98.) This versatility makes TPU adaptable to a wide range of projects, from flexible prototypes to robust end-use parts.</p><h3 dir="ltr">Shock Absorption &nbsp;</h3><p dir="ltr">Thanks to its elastomeric properties, TPU excels at absorbing and dissipating energy. This characteristic makes it an excellent material for vibration dampers, shock absorbers, and protective padding. Products like smartphone cases or sports equipment often utilize TPU for this reason, ensuring protection against impacts.</p><h3 dir="ltr">Weather Resistance &nbsp;</h3><p dir="ltr">TPU can withstand prolonged exposure to environmental elements like UV rays and moisture without significant degradation. This property makes it a reliable choice for outdoor applications, such as weatherproof enclosures, seals, and grips.</p><h3 dir="ltr">Printing Adaptability &nbsp;</h3><p dir="ltr">While flexible filaments can be challenging to print, TPU is among the most user-friendly options in this category. Compared to TPE, TPU offers improved rigidity, which minimizes common printing issues like filament buckling or clogging. This makes it more accessible to users with less advanced 3D printer setups.</p><h3 dir="ltr">Soft Touch and Comfort &nbsp;</h3><p dir="ltr">The tactile qualities of TPU are another advantage. Its soft-touch surface and rubber-like feel make it comfortable to handle, which is why it’s commonly used in grips, ergonomic tools, and wearable technology.</p><h3 dir="ltr">Cost-Effective Prototyping &nbsp;</h3><p dir="ltr">For industries requiring flexible and durable prototypes, TPU offers a cost-effective solution. Its ease of processing and broad compatibility with FDM printers reduce production times and costs compared to traditional manufacturing methods for elastomeric parts.</p><p dir="ltr">With its extensive list of advantages, TPU stands as one of the most versatile and practical materials for 3D printing, enabling a diverse range of functional and aesthetic applications.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/strongest-3d-printer-filament" target="_blank"><em>Strongest 3D Printer Filament: Choosing Between PC, Nylon, TPU, and Others</em></a></strong></p><h2 dir="ltr">Thermal Properties of TPU</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMzMTc0NTAwMDMwLTYxcFJxVUI2ZEFMLl9TTDEwMDBfLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib" alt="ninjaflex"><span class="fr-inner">Popular TPU filament Ninjaflex has a recommended printing temperature of 225–250°C (credit: NinjaTek)</span></span></span></p><p dir="ltr">Understanding TPU's thermal properties is essential for successful 3D printing. These properties influence how the filament behaves during heating, extrusion, and cooling.</p><h3 dir="ltr">TPU Glass Transition Temperature (Tg)</h3><p dir="ltr">The glass transition temperature (Tg) of TPU is low, typically around -30°C depending on its formulation. This low Tg is a defining characteristic of TPU’s flexibility and resilience at room temperature. But why is TPU’s Tg so low compared to other thermoplastics like <a href="https://www.wevolver.com/article/pla-vs-abs" target="_blank">PLA or ABS</a>?</p><p dir="ltr">The answer lies in its chemical structure. TPU consists of alternating soft and hard segments. The soft segments are made of polyether or polyester chains, which are highly flexible and contribute to the material’s elasticity. These segments have low intermolecular forces, allowing the polymer chains to move freely even at low temperatures. As a result, TPU remains soft and pliable well below freezing, making it ideal for applications in cold environments.</p><p dir="ltr">In contrast, the hard segments provide strength and thermal stability but are dispersed throughout the material in such a way that they do not significantly elevate the Tg. This structural balance between flexibility and durability is what sets TPU apart from rigid thermoplastics.</p><h3 dir="ltr">TPU Melting Point&nbsp;</h3><p dir="ltr">TPU does not have a sharp melting temperature but softens over a temperature range, typically 200°C to 250°C.</p><h3 dir="ltr">TPU Heat Resistance</h3><p dir="ltr">Although TPU remains flexible at low temperatures, its heat resistance is limited, with most formulations softening significantly above 60–80°C. This makes TPU unsuitable for high-temperature applications without modification. Some TPU filaments have higher heat resistance. For example, Formfutura's Python Flex 98A material is heat-resistant up to 138°C.</p><h2 dir="ltr">TPU Print Temperature Settings</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733862555601-3d_printer_extruder.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="nozzle"><span class="fr-inner">The nozzle temperature for TPU tends to be in the range of 200–240°C</span></span></span></p><p dir="ltr">Printing TPU requires precise control of several temperature settings and other printing parameters, including the nozzle temperature, bed temperature, and potentially the use of a heated chamber.</p><h3 dir="ltr">Nozzle Temperature</h3><p dir="ltr">The recommended extrusion temperature for TPU generally ranges from 200°C to 240°C, depending on the brand and formulation. Some popular brands and their temperature ranges include:</p><ul><li dir="ltr"><p dir="ltr"><strong>NinjaFlex</strong>: 225–250°C</p></li><li dir="ltr"><p dir="ltr"><strong>SainSmart TPU</strong>: 200–220°C</p></li><li dir="ltr"><p dir="ltr"><strong>Fillamentum Flexfill</strong>: 220–240°C</p></li></ul><p dir="ltr">Choosing the correct nozzle temperature is essential to ensure proper layer adhesion, minimize defects, and maintain the mechanical properties of the printed part. Printing TPU at a temperature that is too low can lead to under-extrusion, resulting in weak parts and poor surface quality. Insufficient heat prevents the material from flowing smoothly, causing inconsistent extrusion and gaps between layers. On the other hand, excessively high temperatures can cause stringing, oozing, or even thermal degradation of the 3D printing filament, leading to brittle prints or discoloration. &nbsp;</p><p dir="ltr">To optimize nozzle temperature, it's advisable to start in the mid-range of the manufacturer’s recommendation and adjust incrementally in 5° steps. Observing the filament flow during a test print can help identify the ideal setting for your printer and filament combination.</p><p dir="ltr">Due to its flexibility, TPU is prone to kinking or compressing inside the extruder, which can lead to clogs. To avoid this issue, ensure that the filament path is constrained and that your extruder gears are not overly tightened. Using a direct drive extruder can help by minimizing the distance TPU travels between the drive gear and the nozzle. Additionally, keeping the nozzle clean and free of residue is crucial. Periodic maintenance and using higher-quality TPU filaments with consistent diameter tolerances can significantly reduce the risk of clogs.</p><p dir="ltr">Proper nozzle temperature and care are key to unlocking TPU’s full potential, enabling smooth extrusion and reliable results across a wide range of applications.</p><h3 dir="ltr">Bed Temperature</h3><p dir="ltr">A heated bed can play an important role in achieving successful prints with TPU. A heated bed can enhance first-layer adhesion and minimize issues like warping or lifting, which can compromise print quality. For most TPU filaments, a bed temperature in the range of 40–60°C is recommended, though the exact setting depends on the filament brand and the specific printer setup. &nbsp;</p><p dir="ltr">When printing with TPU, adhesion to the build plate is essential due to its tendency to contract slightly as it cools. A heated bed provides a stable thermal environment, keeping the base layers adhered to the surface during the printing process. For best results, pairing a heated bed with an adhesive surface like PEI, a glue stick, or specialized printing sheets designed for flexible filaments can further improve reliability. &nbsp;</p><p dir="ltr">Maintaining a consistent bed temperature is especially critical for larger prints or parts with wide, flat bases, as these are more prone to warping. If your printer struggles with adhesion despite proper heating, adjusting the first-layer height and speed, combined with careful leveling of the build plate, can make a significant difference. &nbsp;</p><p dir="ltr">While TPU is more forgiving than some rigid filaments like ABS when it comes to warping, neglecting the heated bed can lead to uneven layers or poor surface quality, especially for prints requiring high precision.</p><h3 dir="ltr">Enclosure</h3><p dir="ltr">Unlike materials like ABS, TPU does not require a closed chamber for printing. However, maintaining a consistent ambient temperature can improve results, particularly for large or intricate prints. If warping occurs, a partially enclosed printer or chamber may help.</p><h2 dir="ltr">Conclusion</h2><p dir="ltr">Printing with TPU can be challenging, but understanding its thermal properties and fine-tuning your printer settings can lead to excellent results. Besides, there's virtually no flexible and reliable alternative at its price point for extrusion-style 3D printing. From its low glass transition temperature to its wide extrusion range, TPU offers unmatched flexibility and durability for various applications. By mastering its print temperatures and bed settings, you can unlock the full potential of this versatile filament.</p><h2 dir="ltr">Frequently Asked Questions</h2><p dir="ltr"><strong>What is the ideal nozzle temperature for TPU?</strong></p><p dir="ltr">Most TPU filaments print well between 200–240°C, depending on the brand and formulation. Always refer to the manufacturer’s recommendations.</p><p dir="ltr"><strong>Do I need a heated bed to print TPU?</strong></p><p dir="ltr">While not always mandatory, a heated bed up to about 60°C can improve adhesion and reduce warping, especially for large prints.</p><p dir="ltr"><strong>Can TPU be printed on a Bowden extruder?</strong></p><p dir="ltr">Yes, but it’s more challenging due to TPU's flexibility. A direct drive extruder is generally recommended for better control.</p><p dir="ltr"><strong>Does TPU require a closed chamber?</strong></p><p dir="ltr">No, TPU does not require a closed chamber, but consistent ambient temperatures can improve print quality for large or detailed prints.</p><p dir="ltr"><strong>How does TPU compare to TPE?</strong></p><p dir="ltr">TPU is generally easier to print and offers greater durability, while TPE is softer and more flexible. TPU is a better choice for wear-resistant applications.</p><h2 dir="ltr">References</h2><p dir="ltr">[1] Miron VM, Lämmermann S, Çakmak U, Major Z. <a href="https://www.sciencedirect.com/science/article/pii/S2452321621002511" target="_blank">Material characterization of 3d-printed silicone elastomers</a>. Procedia Structural Integrity. 2021 Jan 1;34:65-70.</p><p dir="ltr">[2] Yuan S, Shen F, Bai J, Chua CK, Wei J, Zhou K. <a href="https://www.sciencedirect.com/science/article/abs/pii/S0264127517301272" target="_blank">3D soft auxetic lattice structures fabricated by selective laser sintering: TPU powder evaluation and process optimization</a>. Materials &amp; Design. 2017 Apr 15;120:317-27.</p><p dir="ltr">[3] Backes EH, Harb SV, Pinto LA, de Moura NK, de Melo Morgado GF, Marini J, Passador FR, Pessan LA. <a href="https://link.springer.com/article/10.1007/s10853-023-09077-z" target="_blank">Thermoplastic polyurethanes: synthesis, fabrication techniques, blends, composites, and applications</a>. Journal of Materials Science. 2024 Jan;59(4):1123-52.</p>

This article explores the thermal properties of TPU, including TPU glass transition temperature, extrusion and bed temperatures, and best practices for successful 3D printing.

TPU Glass Transition Temperature, Printing Temperature, and Other Thermal Considerations

<section id="isPasted"><p>High-precision is no longer just for micro parts. Boston Micro Fabrication (BMF) emerged as a pioneering force in the 3D printing landscape with its global commercial <a href="https://www.nsmedicaldevices.com/pressreleases/bmf-unveils-microarchtm-the-industrys-most-accuract-and-precise-high-resolution-3d-printer-for-commercial-precision-manufacturing/">launch in 2020</a>, driven by a vision to address an underserved market —the micro-scale 3D printing market. Founded on the principle of addressing the unmet needs within this underserved segment,&nbsp;BMF&nbsp;embarked on a transformative journey to redefine precision manufacturing at the micro level.&nbsp;Pushing the boundaries of precision manufacturing,&nbsp;we have&nbsp;made significant strides in the realm of micro-scale 3D printing. This technology empowered industries like medical devices, electronics, optics and photonics and biopharma to create intricate, high-resolution parts with unparalleled accuracy.</p><p>Yet, as industries advanced, so did their requirements. The demand for larger components with the same level of precision became apparent. BMF’s evolution was not merely about expanding scale but redefining the conventional limits of size in additive manufacturing.</p></section><section><h2><strong>Identifying the Need</strong></h2><p>Through extensive market research and interaction with industry leaders,&nbsp;we&nbsp;identified a growing need for larger parts without compromising on quality and precision. While many traditional manufacturing methods could produce large-scale components, they often sacrificed accuracy or incurred exorbitant costs.</p><p>Industries ranging from electronics to healthcare, and from consumer goods to research &amp; development, were looking for a solution that provided the best of both worlds – larger parts with the precision and quality associated with micro-scale manufacturing. This recognition became the cornerstone of BMF’s new vision – to break free from the confines of micro-scale and embrace larger-scale production without compromising on its commitment to precision.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733126730983-IMG_3917.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Land Grid Array</span></span></span></p><h2 id="isPasted"><strong>The Technological Leap</strong></h2><p>The transition from micro to larger-scale manufacturing required a paradigm shift in technology. BMF embarked on a journey of innovation, investing in cutting-edge research and development to engineer a breakthrough solution, delivering the highest quality parts at a larger size, with built-in automation and speeds suitable for short-run production.</p><p>Leveraging our expertise in high-resolution additive manufacturing, BMF introduced a revolutionary advancement in our technology, the <a href="https://bmf3d.com/25%CE%BCm-series-printers/">microArch</a><a href="https://bmf3d.com/25%CE%BCm-series-printers/">&nbsp;S350</a> a 25µm platform. By marrying precision with scalability, they developed a proprietary system that could produce larger parts while maintaining the same meticulous precision and superior surface quality for which they were renowned. This created the ability to produce high-precision parts outside of the micro field.</p><p>The key lay in the refinement of hardware, software, and material science. Advanced algorithms optimized printing processes, while novel materials were formulated to meet the stringent requirements of larger-scale applications. The result was a game-changing system capable of fabricating larger parts with unparalleled accuracy and surface finish.</p><a href="https://bmf3d.com/wp-content/uploads/2023/12/microArch-S350-door-open.jpg" target="_blank"><br></a><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733126770376-microArch-S350-door-open.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">microArch S350 3D Printer</span></span></span></section><h2 id="isPasted"><strong>Redefining Precision at a Larger Scale</strong></h2><p>Boston Micro Fabrication’s evolution from a micro-scale pioneer to a trailblazer in small macro precision manufacturing represents a pivotal moment in the additive manufacturing landscape. By identifying the unmet needs of industries and investing in cutting-edge technology, BMF has shattered the constraints of micro-scale fabrication.</p><p>As we continue to redefine the boundaries of precision manufacturing, our journey towards larger, high-quality components brings forth a future where intricate, precise manufacturing is not limited by scale. This expansion is set to revolutionize processes in electronics, optics, photonics, and medical sectors, pushing the frontiers of what’s achievable in precision-driven manufacturing. BMF’s future holds a promise of even greater innovation and impact across industries, solidifying its position as a true leader in the world of advanced manufacturing as we look towards 2024 and beyond.</p>

High-precision is no longer just for micro parts. Boston Micro Fabrication (BMF) emerged as a pioneering force in the 3D printing landscape with its global commercial launch in 2020, driven by a vision to address an underserved market —the micro-scale 3D printing market.

High-Precision Isn't Just for Micro Parts

<p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/F5X7waUX8Sc?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><h2 id="isPasted">How a technical service bureau makes FFF the leading 3DP technology for product development and series production</h2><p>Every day, more companies discover the transformative benefits of 3D printing. Although the technology has become significantly more accessible over the years, some businesses may still encounter initial challenges in adopting 3D printing. This is where the experts at IMES3D come in, offering professional support and comprehensive services to ensure a smooth transition and successful implementation.</p><p>Located just 30 minutes from Barcelona’s city center, IMES3D boasts an impressive office equipped with over 60 UltiMaker 3D printers. With over 10 years of experience, their team of experts support professional clients in need of 3D-printed parts. Their clientele spans a wide range of industries, including automotive, food and beverage, military, and medical sectors. This diversity underscores the importance for IMES3D to offer 3D-printed parts in a variety of materials with different properties.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732697022407-picture-1.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 id="isPasted">Challenges customers face</h2><p>IMES3D supports both customers who are new to 3D printing and those who already own 3D printers. Newcomers can receive advice and support in selecting the right printers and setting them up in a suitable environment. Both new and existing users benefit from IMES3D’s team of skilled engineers and designers. They use their expertise to help identify practical applications and create 3D models suitable for printing. With many years of experience and in-house support for both design and 3D printing technology, IMES3D is truly an expertise center for professionals requiring custom part production.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732697042514-picture-2.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 id="isPasted">The printfleet of IMES3D</h2><p>When customers are unable to produce parts themselves, IMES3D can scale up capacity using their UltiMaker printers. This enables them to assist customers with tight deadlines and large volume orders. Many of the printers at IMES3D are UltiMaker S5 models, which offer a large build volume and can use different nozzles to print in a wide range of materials.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732697058969-Fleet-of-printers.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p>Besides common materials such as PLA, ABS, Nylon and TPU, these printers are also able to print more advanced materials. For added strength IMES3D can print parts made from carbon-fiber reinforced nylon which is great for mechanical spare parts. Customers in the food and beverage industry can benefit from FDA-approved materials. For example, parts that carry food products from one machine to another. They can even print flame-retardant or ESD-safe materials. Whenever IMES3D has a request for a very specific use case, they can simply look in the UltiMaker material marketplace, find the right material and add the print profile to UltiMaker Cura.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732697080987-S-line-Application.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">This FDA-safe part is used on a conveyor belt to transport food products, specifically almonds and nuts, along the belt.</span></span></span></p><p id="isPasted">Smaller parts that do not require advanced materials are printed on older UltiMaker models, such as the UltiMaker 3 and UltiMaker 2. Although these models are discontinued, their continuous 24/7 usage is a testament to UltiMaker’s reliability and future-proof design.</p><h2>Adding new possibilities with the Factor 4</h2><p>The latest addition to IMES3D's impressive print fleet is the all-new UltiMaker Factor 4. The machine’s direct drive enables printing with much softer and more flexible materials, opening up new possibilities for applications requiring protection, impact absorption, or enhanced grip. This advancement has allowed IMES3D to expand into a broader range of industrial applications. For example, IMES3D has printed custom bumpers for mobile devices, protecting them from damage after an accidental drop. These materials are also used as an interaction surface for tools to prevent products from being damaged during work or quality control.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732697122519-1732697122519.png" class="fr-fic fr-dib"></p><p>The actively controlled build chamber and new High Temperature (HT) printcore give IMES3D the option to print with various new materials, such as PPS CF. This carbon fiber-reinforced material can withstand even higher temperatures and more tensile stress than materials like carbon fiber-reinforced nylon. These characteristics make it ideal for mechanical parts that endure larger forces or impacts, such as spare parts for manufacturing machines. Parts printed in these materials are often strong enough to replace metal parts, while also being lighter, faster to produce and more cost effective. This makes these materials not only ideal for on-demand spare parts, but also for end-use parts. Especially when the parts are needed in small quantities or with customizations.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732697149161-Applications.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">Additionally, IMES3D utilizes the Factor 4’s&nbsp;<a href="https://ultimaker.com/software/print-process-reporting/">Print Process Reporting</a>. This insightful analysis ensures print quality by highlighting any discrepancies in the print data. After every print job, the operator receives an in-depth report on extrusion parameters deviations from nominal values, their locations, and their severity in the 3D model. Using a suite of sensors in the print head, build chamber, and material loading system, this print process reporting helps to verify and validate part quality before use in the field.</p><h2>Managing a large print fleet through Digital Factory</h2><p>To ensure optimal printer management, IMES3D uses Digital Factory. This platform ensures the entire print fleet is utilized as efficiently as possible. When a 3D print job is sent to the group of printers, Digital Factory selects the right printer for the task. If all printers with the appropriate materials are in use, print jobs can be queued and scheduled. During printing, IMES3D monitors the job over the network to track its progress. Digital Factory also aids in logging and planning regular maintenance, allowing IMES3D to align maintenance schedules with the printers’ workload. Maintenance is now performed regularly during periods when the printers are not required for production.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732697165879-Digital-factory-IMES3D.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p>IMES3D also assists their customers in setting up Digital Factory. This enables their clients to manage print fleets, often spread across multiple locations. Not only can their central 3D printing team manage their printers, but IMES3D can also provide support remotely from their own offices. Customers can create an internal catalog of 3D models and prints, enabling anyone in their company to simply select the part they need and start the print.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732697182017-Fleet-of-printers-IMES3D.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p>IMES3D has proven to be a professional and reliable expertise center for 3D printing, and with the support of UltiMaker's local partner in Spain,&nbsp;<a href="https://sicnova3d.com/" id="isPasted">Sicnova</a>, IMES3D has developed into the service bureau with the largest number of UltiMaker printers in the world. With over 60 UltiMaker printers creating large quantities of parts for so many different industries with different requirements, they really showcase the agility for 3D printing. The UltiMaker Factor 4 is a big step up, extending their possibilities. This enables them to keep innovating and explore even more solutions for their customers.</p>

Every day, more companies discover the transformative benefits of 3D printing. Although the technology has become significantly more accessible over the years, some businesses may still encounter initial challenges in adopting 3D printing.

IMES3D: Expert Support for Industry-Level 3D Printing

An engineer’s guide to understanding the state
of the art in metal 3D Printing

Metal 3D Printing Technology Report

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