TPU Additive Manufacturing Providers
Thermoplastic polyurethane is an elastomeric material that combines rubber-like flexibility with abrasion resistance and high elongation at break. TPU is 3D printed via FDM, SLS, or MJF to produce gaskets, seals, vibration dampeners, wearable devices, and soft-touch grips. Shore hardness ranges from 60A to 95A depending on the grade. Find verified TPU AM providers on ForgedLink, screened for hardness control, dimensional accuracy in flexible geometries, and surface finish quality.
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Why TPU fills the elastic AM gap between rigid plastics and silicone
TPU (thermoplastic polyurethane) is the dominant elastomeric material in AM — filling the performance gap between rigid engineering polymers (nylon, ABS) and silicone rubbers that remain extremely difficult to print. TPU's mechanical profile is highly tunable: Shore hardness ranges from 60A (soft, gel-like, high damping) to 95A (semi-rigid, structural, low hysteresis), achieved by varying the hard/soft-segment chemistry. All TPU grades share the elastomeric fundamentals: elongation at break typically 300–600%, recovery from deformation, and excellent abrasion resistance — outperforming natural rubber on abrasion in most comparisons.
Three AM processes produce TPU parts. FDM TPU filament is widely available and affordable, but printing flexible TPU on standard FDM machines is technically demanding — the soft filament feeds unpredictably and requires slow print speeds, direct-drive extruders, and careful retraction settings. SLS TPU (BASF Ultrasint TPU01, EOS TPE) and MJF TPU (HP 3D High Reusability TPU) produce isotropic, support-free parts with better surface finish and more consistent hardness, making them the preferred route for production functional parts. The provider pool for SLS/MJF TPU is smaller than for nylon but growing rapidly.
Where AM TPU parts are used in production
Gaskets, seals, and custom diaphragms
Custom-geometry gaskets and seals in Shore 70A–85A TPU for pneumatic, hydraulic, and fluid-handling applications — printed in hours vs days for machined elastomers, and geometry-adapted for the specific assembly without tooling.
Vibration dampeners and shock-absorbing mounts
Lattice-geometry TPU dampers with tunable energy-absorption characteristics — a unique AM capability impossible with moulded elastomers. Used in motorsport, aerospace equipment mounts, industrial machinery, and consumer electronics packaging.
Wearable straps, bands, and orthotic devices
Skin-contact wearables including smart-watch straps, custom orthotic footbeds, compression garments, and medical compression sleeves. SLS and MJF TPU parts can be produced in patient-specific geometries from scan data.
Soft-robotics grippers and compliant mechanisms
TPU flexible elements in soft robotic grippers that adapt to irregular object geometries — FDM multi-material (rigid + TPU) and SLS single-part flexible-rigid composites are both used in research and production cobots.
Footwear outsoles, midsoles, and lattice cushioning
SLS TPU outsoles and lattice midsoles for performance footwear — HP's collaboration with major sportswear brands on MJF TPU midsoles has established this as a production-volume AM application.
Protective covers, cable grommets, and strain reliefs
Custom cable management, strain relief boots, and protective covers for electronics and industrial equipment — geometry adapted to the specific cable bundle or connector without moulding tooling.
Common AM TPU grades
Standard FDM TPU filament (generic, Shore 85A–95A)
Widely available from commodity filament suppliers. Shore hardness varies by supplier — confirm the Shore A value before specification. Requires direct-drive extruder and slow print speeds (~20–30 mm/s) for reliable deposition. Anisotropic Z-axis properties; functional but not production-grade for most seal and damping applications.
BASF Ultrasint TPU01 (SLS, Shore 87A)
The workhorse SLS TPU. Shore 87A, tensile strength ~28 MPa, elongation ~420%. Isotropic, support-free, excellent surface finish for SLS. The default specification for functional SLS TPU parts. Available on Formlabs Fuse 1 (modified), EOS P396, and dedicated SLS platforms.
HP 3D High Reusability TPU (MJF, Shore 88A)
HP's MJF-compatible TPU. Similar hardness and properties to Ultrasint TPU01 but produced via MJF for higher throughput and better build isotropy. Full-colour printing capability on HP 5200 series enables colour-coded functional TPU parts.
Duraform Flex (3D Systems SLS, Shore 65A–70A)
Softer SLS TPU grade — lower Shore A for applications requiring more compliance. Lower tensile strength and elongation than TPU01. Used for very soft seals, anatomy-mimicking medical models, and high-damping applications.
TPU 95A (ULTEM-compatible FDM, high-temp)
Higher-durometer TPU grades for FDM printing on high-temperature platforms — used for automotive seals and industrial gaskets where the service temperature exceeds standard TPU limits (~80°C continuous for commodity grades vs ~100°C for TPU 95A specialty grades).
Medical-grade TPU (ISO 10993 qualified)
Biocompatible TPU grades for skin contact and limited-use medical applications. Requires specific material certification and often a qualified provider under ISO 13485. Available from select powder-bed providers for custom orthotic and wearable medical devices.
When to choose AM TPU over silicone, nylon, or moulded rubber
TPU vs silicone for seals and flexible parts: AM TPU wins on printability — silicone AM is extremely niche (only a handful of specialist providers, limited geometry, high cost) while TPU is widely available. Silicone wins on biocompatibility for implantable use, extreme temperature range (-60°C to 200°C+), and gas permeability for specific applications. For most custom gaskets and seals in industrial and consumer applications, TPU is the practical choice; for medical implantable and extreme-temperature seals, silicone or FFKM.
AM TPU vs moulded rubber for custom gaskets: AM wins decisively at low volume (1–50 parts) and complex geometry — a custom gasket profile can be produced by AM in 24 hours vs weeks for tooling. Moulded rubber wins at volume (>500 units of identical geometry) on per-part economics. For prototype and small-batch custom seals, AM TPU is standard practice.
Shore 85A vs Shore 65A TPU: Shore 85A (Ultrasint TPU01, HP MJF TPU) is the production default — good balance of stiffness, elongation, and printability. Shore 65A–70A (Duraform Flex) for applications requiring high compliance and damping — softer seats, anatomy models, and grips. Higher durometer (95A) for semi-rigid seals and covers that must maintain geometry under assembly load.
FDM TPU vs SLS/MJF TPU: FDM TPU for prototyping and very low volumes (1–10 parts) where SLS/MJF build economics aren't justified. SLS and MJF TPU for any production application — isotropic properties, consistent hardness, better surface finish, support-free complex geometry. The anisotropy and surface roughness of FDM TPU are significant limitations for seal and damping applications.
Cost and lead time for AM TPU parts
FDM TPU parts deliver in 1–3 days from most providers. SLS and MJF TPU typically delivers in 3–7 days including post-processing (bead blast, surface cleaning). Medical-grade TPU under ISO 13485 runs 2–3 weeks. Custom lattice geometry for tuned-damping applications may add 1–2 days for FEA verification before printing.
Indicative pricing for a 100 cm³ SLS TPU part (single, bead blasted): £90–£220 / €107–€260. FDM TPU at similar volume runs lower — £40–£120 / €47–€142 — but with inferior mechanical properties. At batch volumes (50+ parts), SLS/MJF TPU drops toward £40–£90 / €47–€107 per part from build packing economies. Custom-geometry gaskets with tight tolerances may require CNC-machined mating surfaces in the receiving assembly for reliable sealing.
Related processes & materials
Frequently asked questions
What Shore hardness should I specify for AM TPU seals?
For static and low-dynamic seals (gaskets, cover seals): Shore 80A–90A provides enough stiffness to maintain geometry under assembly compression while giving adequate compliance for sealing. For dynamic seals under repeated compression (bellows, flexible diaphragms): Shore 70A–80A for better fatigue compliance. For vibration dampers and soft grips: Shore 60A–75A for maximum energy absorption. If you're unsure, Shore 85A (Ultrasint TPU01 default) is a good starting point and covers most industrial seal and damping applications.
Why is TPU difficult to print on standard FDM machines?
Standard Bowden-drive FDM extruders rely on the filament being rigid enough to act as a push rod through the PTFE tube. TPU filament is elastic and compressible — it buckles and coils in the Bowden tube rather than pushing through consistently, causing under-extrusion and clogging. Direct-drive extruders (mounted directly on the printhead with no Bowden tube) solve this by minimising the unsupported filament path. Additionally, TPU requires slow speeds (15–30 mm/s), minimal or zero retraction, and often a dry filament environment to avoid moisture-driven voids.
Can AM TPU parts be used as food-contact seals?
Yes, with the right grade and provider documentation. Food-contact TPU must be certified to FDA 21 CFR or EU Regulation 10/2011 for the specific food type and contact conditions. The base polymer and any colourants / post-processing agents must be compliant. SLS/MJF TPU parts have open porosity that can harbour bacteria unless surface-sealed; food-contact seals typically require infiltration or coating. Always confirm food-contact scope with the provider — not all TPU grades are cleared for food-contact use, and ForgedLink provider profiles specify this capability.
Is AM TPU suitable for outdoor UV-exposed applications?
Standard TPU (polyester-based) has moderate UV resistance and will yellow and degrade over extended outdoor exposure. Polyether-based TPU grades have better hydrolysis resistance (important for humid environments) and slightly better UV stability. For outdoor applications, UV-stabilised TPU grades are specified where available, or consider ASA (acrylic-styrene-acrylonitrile) for the rigid elements and a UV-stabilised elastomeric coating for flexible sections. For continuous outdoor UV exposure, moulded EPDM or UV-stabilised silicone is generally a better choice.
Can AM TPU be used for lattice structures with tunable stiffness?
Yes — and this is one of the most compelling AM TPU applications. Lattice geometry (gyroid, octet, BCC cells) in TPU creates a structural soft-body with compressive stiffness tunable by lattice density and cell size, independent of the base material hardness. This enables customised cushioning profiles (e.g. graduated stiffness in a footwear midsole or a seating cushion) that are impossible to achieve with moulded homogeneous elastomers. FEA simulation of the lattice behaviour before printing is standard practice for production lattice-TPU applications.