Kapsula: Extreme Protection for Sensitive Devices

Original story written by UltiMaker partner Crea3D

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Kapsula is an innovative solution designed to provide extreme protection for electronic devices in harsh environments. Utilizing advanced materials like polyphenylene sulfide reinforced with carbon fiber (PPS CF), Kapsula offers unparalleled durability against physical impacts, high temperatures, and environmental stressors.

This robust protection ensures the integrity and functionality of critical electronic equipment and vials containing medicines or biological samples, making Kapsula essential for both civilian and military applications.

Despite its high resistance, Kapsula remains lightweight at only 250g and can be produced cost-effectively via 3D printing, allowing for on-site manufacturing even in war zones. Kapsula can be deployed in various ways, including drone drops from significant heights or carried by personnel due to its ergonomic design.

Technical Approach

Kapsula is designed as a 3D printed truncated icosahedron, using PPS CF material for high strength and thermal stability. It features a TPU core with a gyroid fill pattern for impact absorption, structural textures for reinforcement, and customizable internal shells.

The truncated icosahedron was selected due to its superior mechanical properties. This shape is renowned for its ability to evenly distribute forces, minimizing stress concentrations that could lead to material failure.

The 3D printer used is the new UltiMaker Factor 4, specifically designed to print challenging materials such as PPS CF.

Advanced features include an integrated GPS sensor and potential additional electronic countermeasures.

Ergonomic Design and Manual Operation

Kapsula's design is not only robust but also ergonomic. It is small enough to fit comfortably in one hand, making it easy to carry and manipulate.

The capsule features a simple manual opening mechanism, designed to be operated without tools, ensuring quick and easy access in the field.

This "rustic" approach to opening means that soldiers and field personnel can rapidly deploy the device without needing specialized equipment.

Advanced Internal Features

Inside, Kapsula can include a layer of thermoplastic polyurethane (TPU) printed with a gyroid fill pattern. This gyroid structure is particularly effective at absorbing impacts, providing an additional layer of protection for the electronic devices housed within.

The TPU core acts as a shock absorber, preventing damage from drops and other impacts.

This internal design can be customized to fit various objects, ensuring optimal protection for a wide range of equipment.

Structural Textures and Reinforcements

To further enhance its durability, Kapsula incorporates structural textures applied to its internal surfaces. These textures are designed to reinforce the model, increasing its resistance to impacts and environmental stressors.

The textures and topologies are carefully calculated and designed to maximize strength while minimizing weight, ensuring that Kapsula remains both lightweight and incredibly strong.

It can be scaled to different sizes to accommodate various applications and can be enhanced with an intermediate metal layer for additional resistance.

Development Status

Prototype: successfully demonstrated in relevant environments, including high-temperature and high-impact scenarios (drone drop).

Testing: conducted in various conditions to validate performance claims. Ongoing test campaigns include extended environmental exposure and cyber-physical stress testing.

Multiple use potential

Kapsula effectively meets both military and civilian needs. In military contexts, it protects battlefield communication devices, ensuring reliable data transmission and preventing data loss during combat. Its lightweight, drone-compatible design allows for the safe delivery of sensitive equipment or supplies to remote locations.

Additionally, Kapsula acts as a durable black box for drones, safeguarding data in crashes.

For disaster response or civilian use, Kapsula ensures continuous operation of monitoring equipment and safe transport of medical samples, biological specimens, or evidence requiring secure handling or drone delivery.

In commercial applications, it protects industrial equipment from hazards.