3D printing with TPE – From experiment to practice

3D printing with TPE 

Since 2018, there has been a steady increase in the importance of 3D printing with thermoplastic elastomers (TPE). What initially began as a niche interest has developed over the years into an independent field of application with clear technological requirements, new process solutions, and increasing scientific penetration.

The first inquiries came mainly from manufacturers of 3D printing machines. The tenor was often similar: “Who supplies TPE filaments?” At that time, the focus was particularly on TPU materials with hardnesses above 75 Shore A. These materials were already available as filaments and could be processed relatively well. Accordingly, they shaped the start of this trend.

Limitations of filament-based systems with soft materials

It quickly became apparent that these experiences could not be easily transferred to softer TPE materials. Significant processing challenges were encountered for all six TPE subgroups (TPS, TPU, TPV, TPO, TPC, TPA) in the hardness range below 70 Shore A. 

Feed, process stability, and component quality could only be controlled to a limited extent with filament-based systems. The industry intensively searched for alternative processing approaches.

New solution: granule-based 3D printing

Various machine manufacturers began projects in collaboration with TPE material suppliers – the result: granule-based 3D printing systems for TPE that serve a wide range of hardnesses. 

The direct use of granulate allows for better control of material-specific properties, and even softer TPE materials, up to the super-soft range, can be processed stably. This optimized processing method opened up new freedoms in terms of material selection and component design.

A trend is developing into daily business

To date, these manufacturing systems have been continuously refined. Improvements have had an impact on component quality and process stability, among other things. The spectrum ranges from very small, filigree structures to large component geometries that can be manufactured in printing systems with large installation spaces. 

At the same time, there has been a significant deepening of understanding of process parameters, material behavior, and component performance.

Enquiries about 3D printing with TPE are now part of everyday life. Basically, it can be said that a very wide range of products is available and that most TPE materials can in principle be processed in granulate-based 3D printing. In addition, a wealth of experience with manufacturing parameters is now available. 

However, this data and these recommendations are no substitute for project-specific preliminary tests. Rather, they serve as a reliable starting point for joint development with machine manufacturers and TPE suppliers.

Focus on 3D printing

The areas of application for TPE in 3D printing are currently mainly in medical technology, sports and leisure, and robotics. The focus is often on individually manufactured components that are customized to the user, as well as components with complex geometries. 

Through the targeted combination of shape and material, functions can be integrated directly into the component, which is only possible to a limited extent with conventional manufacturing processes.

In our experience, exciting ideas come from the academic world. Colleges and universities around the world are intensively engaged in 3D printing of elastic materials. In Europe and the USA, KRAIBURG TPE supports various topics and working groups by providing material samples and expert advice. 

We work with students and researchers worldwide who are developing new solutions and future applications. Short development and implementation times, comparatively low investment costs, and a high degree of freedom in material selection and design are leading to a large number of scientific publications.

Another development step is emerging with the use of AI-supported image recognition and image processing. These technologies open up new possibilities, for example in automated component evaluation, process monitoring, or the individualized adaptation of geometries based on digital data.

Conclusion

The development of 3D printing with TPE is therefore not a short-term trend, but a dynamic field of technology that will continue to be characterized by interdisciplinary collaboration. The exchange of expertise on material- and process-related issues remains a central component in further tapping the existing potential of this manufacturing technology.

What experience have you had with 3D printing? We look forward to hearing from you.