TPU is a flexible, rubber-like thermoplastic commonly used in 3D printing for its elasticity and durability. Unlike rigid materials such as PLA or ABS, TPU provides excellent flexibility, abrasion resistance, and impact absorption, making it ideal for printing objects that need to bend, stretch, or withstand wear. It is particularly valued in industries like footwear, automotive, and consumer electronics.

Common Uses:

• Phone cases
• Wearable devices
• Flexible joints and hinges
• Seals, gaskets, and bushings
• Protective gear and sports equipment

TPU Variations:

TPU 95A

TPU 95A refers to the material's Shore hardness, meaning it's slightly stiffer but still flexible.

This variation's additional stiffness makes it ideal for applications requiring moderate flexibility, such as phone cases or wearable components.

TPU 85A

Softer and more elastic than 95A, TPU 85A offers greater flexibility and is suitable for parts that require more stretch.

For example, it is suitable for printing highly flexible objects, such as seals, gaskets, and rubber-like parts.

TPU CF (Carbon Fibre)*

Carbon fibre-infused TPU offers increased rigidity while retaining some flexibility, making it stronger and more dimensionally stable.

It’s ideal for lightweight, durable parts that still need some elasticity, such as automotive components.

*For more information on printing with TPU CF, refer to the Carbon Fibre guide. 

TPU Variations Comparison Table

Material	Flexibility	Abrasion Resistance	Impact Resistance	Common applications
TPU	High	High	High	Flexible joints, phone cases, wearables
TPU 95A	Medium	High	High	Phone cases, wearables, functional prototypes
TPU 85A	Very High	High	Very High	Seals, gaskets, flexible joints, rubber-like parts
TPU CF	Low/Medium	Very High	High	Automotive parts, lightweight durable parts

 

Pros and Cons of TPU:

Pros:

• Highly flexible: TPU’s flexibility is its defining characteristic, making it ideal for parts that need to stretch or compress.
• Abrasion resistance: TPU is highly resistant to wear and tear, making it durable even in demanding environments.
• Impact resistance: TPU can absorb impact effectively, making it ideal for protective parts or components subject to mechanical stress.
• Chemical resistance: TPU offers good resistance to oils, greases, and many solvents.
• Good layer adhesion: TPU adheres well between layers, reducing the risk of delamination.

Cons:

• Difficult to print: TPU’s flexibility can make it challenging to print on standard 3D printers, as it is prone to jamming in direct drive extruders.
• Slow print speeds: Due to its flexibility, TPU requires slower print speeds to maintain accuracy and prevent deformation during printing.
• Less detail: TPU prints may lack the sharpness and fine detail achievable with rigid filaments.
• Poor bridging: TPU struggles with printing bridges and overhangs without support due to its flexible nature.
• Requires special handling: TPU is more prone to stringing and oozing, so careful tuning of retraction and temperature is needed.

Storage Tips:

TPU is hygroscopic and can absorb moisture from the air, leading to poor print quality if not stored properly:

• Store in an airtight container with desiccants to avoid moisture absorption.
• Dry the filament if necessary (using a filament dryer or low-temperature oven at around 40°C for several hours).
• Use a filament drybox during printing to maintain print quality, especially in humid environments.

Environmental Considerations:

TPU has a mixed environmental impact due to its synthetic nature:

• Not biodegradable: TPU is not biodegradable, but it can be recycled under the right conditions.
• Long-lasting: Due to its durability and flexibility, TPU can have a long service life, reducing the frequency of replacement for certain products.
• Chemical resistance: While resistant to chemicals, TPU’s production and disposal may have environmental impacts, so recycling is preferred.

Generic Print Settings for TPU:

Extruder Temperature: 210°C – 230°C

Bed Temperature: 40°C – 60°C (a heated bed helps with adhesion but is not always required)

Print Speed: 15 – 30 mm/s (slower speeds are recommended for better accuracy)

Bed Adhesion: Use a glue stick or painter’s tape to aid adhesion; TPU can stick well to most bed surfaces

Retraction: Minimal retraction (1 – 3 mm) to avoid clogging, with slower retraction speeds

Cooling: Moderate cooling, around 30% to 50%, to help with print quality without negatively affecting layer adhesion

Please note, as with other materials, print settings may vary depending on the specific filament. Always check the recommended settings from the manufacturer, usually listed on the spool’s packaging or the supplier’s website.

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