TPU in Industrial 3D Printing: Elastic Materials for Functional Applications

Thermoplastic polyurethane (TPU) has established itself as a versatile material for elastic components in additive manufacturing. Especially in industrial applications where flexibility, durability, and design freedom are equally important, TPU demonstrates its strengths. The company Speedpart relies on selective laser sintering (SLS) to produce functional components made of TPU, ranging from prototypes to small series.

TPU belongs to the class of thermoplastic elastomers (TPE) and combines the properties of conventional plastics with rubber-like elasticity. Thanks to its thermoplastic processability, it can be additively manufactured without the limitations of traditional elastomers. In the laser sintering process, TPU powder is melted layer by layer using a laser, resulting in components with high dimensional accuracy and reproducible quality. Speedpart uses TPU with a Shore hardness of 70A – currently the softest hardness that can be economically processed in polymer laser sintering.

The material is suitable for a wide range of applications. In medical technology, for example, flexible connectors or orthopedic insoles are produced, while in the automotive industry, seals, boots, and cable grommets benefit. TPU also exhibits high resistance to abrasion, oils, and chemicals. Its grippy surface texture and the ability to be chemically smoothed or dyed make it attractive for visible and ergonomically relevant components as well.

Despite its versatile properties, TPU in laser sintering reaches its limits when very soft Shore hardnesses or specific color and transparency requirements are needed. In such cases, processes like PolyJet or vacuum casting are used, offering complementary material options. Nevertheless, TPU illustrates how additive manufacturing is increasingly advancing toward industrial series production. For companies, it opens up new paths to functional, customizable, and cost-effective solutions in elastic 3D printing.