Flexible filaments such as TPU open up numerous new application possibilities in FDM printing – especially when they are specifically combined with other materials. A current project on the YouTube channel “Functional Part Friday” shows how functional bellows can be produced using alternating layers of TPU and PLA.
The method makes targeted use of the material properties of both plastics: While TPU provides flexibility, PLA layers serve as a temporary separating layer. Both materials are applied layer by layer in a two-color printing process. The PLA is then manually separated from the TPU, creating an elastic bellows with a defined folded structure. Precise coordination of the layer structure and clean decoupling after printing are crucial here.
Technically, the process poses a number of challenges. For example, it turned out that not every TPU manufacturer delivers equally good printing results. The processing of TPU using Bambu Lab’s automatic material system (AMS) was particularly problematic. In combination with the AMS, there was insufficient feeding and a brittle print image, which is why the team manually bypassed the material feed system. A stable solution was only possible with a printer with independent extruders.
The benefits of such TPU bellows range from covers for machine guides to air conveying or special solutions in model making. The method impressively demonstrates how complex, functional components can be realized through the targeted change of materials in the layer structure – provided that the printer and software allow precise control.
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