TPU applications: Flexible 3D printing for real-world performance

The material variety of additive manufacturing is expanding to meet the needs of various industries and fields. From rigid PLAs to nylon filaments, applications are no longer limited to traditional manufacturing methods and materials. With more and more flexible materials entering the game, manufacturers and designers can now experiment with filaments for applications requiring more elasticity.

What are TPUs?

Flexible filaments are made of Thermoplastic Elastomers (TPE) which are a blend of hard plastic and rubber, allowing the material to be stretched and flexed easily.

There are several types of TPE, with Thermoplastic polyurethane (TPU) being the most commonly used among 3D printing filaments.

The filament comes with advantages, such as:

• Flexible and soft
• Excellent vibration-damping
• Long shelf life
• Good impact resistance

However, it does require some experience to print TPU filaments properly, and in case softer TPUs are printed, there are some hurdles to overcome while printing with a Bowden tube extruder.

The hardness of TPU is measured on the Shore A or Shore D scale. Softer, more flexible TPUs are measured on Shore A, with higher values indicating a harder and less flexible material. Shore D is used for harder, more rigid TPUs and measures their higher hardness and stiffness.

We know the importance of using the right material for the right job. Whether you’re producing protective gear, refining packaging processes, or iterating on product designs, TPU offers the adaptability you need - and with the UltiMaker ecosystem, printing it is easier than ever.

Why TPU?

TPU is known for its impressive elasticity, wear resistance, and impact strength. These properties make it a go-to material for applications that require flexibility under pressure. Its ability to deform and return to shape makes it ideal for both functional prototypes and end-use parts that encounter dynamic forces.

1. Defense: Cushioning where it counts

In protective equipment, such as helmets used in defense, shock absorption is critical. TPU is used to create protection cushions that help absorb and disperse impact forces, enhancing safety without adding excessive weight or rigidity.

Interested in more applications in defense? Read our deep-dive into defense applications and benefits of 3D printing.

2. Packaging: Precision meets flexibility

In fast-paced packaging lines, delicate handling is essential, especially when working with fragile or irregularly shaped products.

Bumpers help guide bottles and containers through production lines. At Heineken’s bottling plant in Seville, Spain, TPU bumpers are used to prevent glass breakage during high-speed operations, proving that even minor components can have a major impact.

Another application is the gripper, suitable for the beverage industry. With a soft, flexible gripper and a more rigid PET carbon fiber reinforced "arm”, this part is a prime example of dual material application. Thanks to its custom soft TPU gripper, it can easily guide bottles along the belt without breaking or damaging the glass.

3. Footwear: Flexibility for the feet

TPU is also making strides in the design and fashion industries, particularly in footwear. Designers use it to create custom insoles and flexible shoe components, allowing for ergonomic testing and rapid iteration. Its comfort and durability make it ideal for prototypes and end-use parts in performance shoes.

Barcelona-based Footwearology specializes, among other things, in 3D printed sneakers and other footwear. Working together with footwear designers from all over the world, Footwearoogy innovates sneakers and high-heels using TPU.

4. Automotive: Custom tooling with TPU

In the automotive industry, flexible filaments used in 3D printed tools play a crucial role in streamlining assembly processes. Since vehicles undergo multiple handling and assembly stages before shipping, it's essential to protect them from damage or surface scratches - something these specialized tools help achieve effectively.

For example, Volkswagen used TPU to create custom badges to place vehicle emblems accurately. Thanks to its soft surface, the emblems could be attached to the car without risking the surface.

5. Logistics/Maintenance: Custom protection casing in TPU

Logistics and maintenance departments in manufacturing or transport companies often make use of customized casings printed in TPU to protect their devices from damage and store them easily.

This is a personalized case for electronic devices, used in airport warehouses made by IMES3D. The soft TPU protects the casing and is customized to the size of the device. Color is used to code the different devices and locations. Some devices include magnets to connect them to a station. This device was printed in a softer TPU (vibration-dampening and impact-resistant) to also protect the device when it falls.

6. Sports bike manufacturing: Custom steering handle extension

For this Wielerhuis van der Marel steering handle extension, a dual extrusion 3D print was used to combine TPU 95A with Nylon CF Slide. The brackets, which were mounted directly onto the carbon bike frame, featured a soft TPU 95A interface to protect the frame’s surface from potential damage.

This smart material pairing ensured a secure, functional connection while preventing wear on the carbon parts - an ideal application for hybrid material printing in sensitive, high-performance components.

Flexible filament, seamlessly integrated

With the UltiMaker ecosystem, printing with flexible materials like TPU doesn’t require guessing. Our printers are made to handle the specifics of flexible filament, with fine-tuned profiles and material compatibility built into the UltiMaker Cura software.

And with open filament compatibility, you're free to choose from both UltiMaker-branded and third-party TPU materials, giving you the flexibility to match your exact performance and budget requirements.

From packaging lines to product design labs, TPU is proving itself as an indispensable material across industries. Combined with the reliability and ease of the UltiMaker ecosystem, it's never been easier to turn flexible ideas into functional parts.

Ready to explore the potential of TPU with UltiMaker?

Try printing your next flexible part with UltiMaker and discover how industrial performance meets everyday usability. Choose UltiMaker’s TPU or discover third-party filaments through UltiMaker Marketplace for your next application. With UltiMaker, you have the freedom of choice.

Contact our experts today and see how additive manufacturing can benefit your business