Material: Ultrasint TPU01 88A (MJF)
TPU 3D printing creates flexible, high-performance parts with a 88A Shore hardness, providing excellent shock absorption and energy return.
TPU 3D printing creates flexible, high-performance parts with a 88A Shore hardness, providing excellent shock absorption and energy return.
Material Intro
Ultrasint™ TPU01 is a flexible and durable thermoplastic polyurethane (TPU), offering excellent impact resistance, energy return, wear performance, and tear resistance. TPU 3D printing is ideal for parts requiring flexibility, shock absorption, and long-lasting performance.
MJF TPU behaviour
Flexibility & energy return
TPU 3D printing produced parts with excellent flexibility and high energy return, making it ideal for applications requiring dynamic motion and impact absorption, such as footwear cushioning or protective gear
Abrasion & tear resistance
Ultrasint™ TPU01 is highly resistant to abrasion, wear, and tear, ensuring durable performance in parts that experience continuous stress, such as seals, gaskets, and protective components
Chemical resistance
Ultrasint™ TPU01 offers strong resistance to oils, greases, and chemicals, making it reliable in harsh industrial environments or for outdoor applications exposed to the elements
Temperature stability
The material maintains its properties at temperatures up to 80°C, providing stability and performance in environments with fluctuating temperatures or moderate heat exposure
TPU 3D printing produced parts with excellent flexibility and high energy return, making it ideal for applications requiring dynamic motion and impact absorption, such as footwear cushioning or protective gear
Ultrasint™ TPU01 is highly resistant to abrasion, wear, and tear, ensuring durable performance in parts that experience continuous stress, such as seals, gaskets, and protective components
Ultrasint™ TPU01 offers strong resistance to oils, greases, and chemicals, making it reliable in harsh industrial environments or for outdoor applications exposed to the elements
The material maintains its properties at temperatures up to 80°C, providing stability and performance in environments with fluctuating temperatures or moderate heat exposure
TPU 3D Printing PROS |
TPU 3D printing CONS |
|---|---|
| + Shock Absorption and Rebound: Provides excellent impact resistance while efficiently returning to its original shape, making it ideal for applications requiring energy return. |
– Higher Material Costs: The specialised properties of TPU can result in higher part costs compared to standard polymers. |
| + Wear and Tear-Resistant: Delivers exceptional durability, outperforming many materials in high-friction environments, ensuring longevity in demanding applications. |
– Longer Lead Times: Requires more production time due to material-specific processes and post-processing steps. |
| + Flexible and Durable: Combines flexibility with strength, making it perfect for applications like footwear and automotive components that require both adaptability and resilience. |
– Additional Design Constraints: Avoid features like holes, tubes, engraved details, and sharp internal corners, as they attract unfused powder. |
| + Smooth Surface Finish: Minimal layer line visibility, offering a finish comparable to injection moulding. |
– Limited Colour Availability: Only available in natural or black, restricting colour variety for design specifications. |
| + UV and Weather Resistant: Performs excellently in outdoor environments, resisting damage from sunlight and harsh weather conditions. |
|
| + Resistance to Oils, Greases, and Chemicals: Ideal for industrial applications, offering reliable protection against exposure to harsh substances such as oils, greases, and chemicals. |
Material hardness guide: TPU 3D printing in context
This chart visually compares TPU01 with familiar materials like silicone straps, tool grips and our MJF PA12. In its solid form, Ultrasint TPU01 has a Shore hardness of 88-90A, but incorporating a lattice structure into the design can soften it significantly. Lattice structures allow for adjusting hardness, though it’s important to remember that hardness doesn’t mean elasticity. TPU01 strikes a balance between resilience and flexibility, but it’s not as elastic as softer rubbers like silicone 3D printing.
TPU01 finishes
TPU 3D printed parts start with a natural finish, but additional post-processing options are available to enhance the surface appearance and mechanical properties, depending on your application needs.
Finish: As printed
The natural finish offers a smooth, slightly matte surface. The material’s flexibility is maintained, with minimal visible layer lines and a fine texture suitable for functional prototypes and end-use parts.
Finish: Black dye (inc. shot peen)
Dyeing provides a deep black finish while maintaining the flexibility and durability of the material. The process enhances the overall aesthetic and adds a uniform color throughout the part.
Finish: Vapour smoothing
Vapour Smoothing enhances both the texture and the performance of TPU01 parts. This process creates a smooth, sealed surface while improving elongation at break and moisture resistance, making it perfect for applications requiring airtight or watertight properties.
Finish: As printed
The natural finish offers a smooth, slightly matte surface. The material’s flexibility is maintained, with minimal visible layer lines and a fine texture suitable for functional prototypes and end-use parts.
Finish: Black dye (inc. shot peen)
Dyeing provides a deep black finish while maintaining the flexibility and durability of the material. The process enhances the overall aesthetic and adds a uniform color throughout the part.
Finish: Vapour smoothing
Vapour Smoothing enhances both the texture and the performance of TPU01 parts. This process creates a smooth, sealed surface while improving elongation at break and moisture resistance, making it perfect for applications requiring airtight or watertight properties.
Ideal for:
flexible rubber-like components
- Industrial equipment
- Healthcare and medical
- Automotive, aerospace and defence
- Footwear and performance sports
- Agricultural technology and robotics
Ultrasint™ TPU01’s flexibility, durability, and wear resistance make it ideal for demanding applications in various industries.
TPU 3D printing – technical data
| General properties | Test method | Value |
|---|---|---|
| Natural colour | N/A | Grey |
| Particle size | ISO 13320 | 80 µm |
| Sintered part density | DIN EN ISO 1183-1 | 1.1 g/cm3 |
| Mechanical / electrical properties* | Test method | Value |
|---|---|---|
| Tensile strength, max load, XY | DIN 53504 | 9 MPa |
| Tensile strength, max load, Z | DIN 53504 | 7 MPa |
| Tensile modulus, XY | ISO 527-2 | 85 MPa |
| Tensile modulus, Z | ISO 527-2 | 85 MPa |
| Elongation at break, XY | DIN 53504 | 280% |
| Elongation at break, Z | DIN 53504 | 150% |
| Flexural modulus, XY | DIN EN ISO 178 | 75 MPa |
| Flexural modulus, Z | DIN EN ISO 178 | 74 MPa |
| Charpy notched impact strength, 23°C, XY | DIN EN ISO 179-1 | No break |
| Charpy notched impact strength, -10°C, XY | DIN EN ISO 179-1 | 46 kJ/m2 |
| Dielectric strength (XY) | ASTM D149 | 4.38 kV/mm |
| Dielectric strength (Z) | ASTM D149 | 5.81 kV/mm |
| Volume resistivity (XY) | ASTM D257 | 1.45 × 1011 Ω·cm |
| Volume resistivity (Z) | ASTM D257 | 6.79 × 1010 Ω·cm |
| Specific surface resistivity (XY) | IEC 62631-3-2 | 5.5 × 1011 Ω |
| Thermal properties | Test method | Value |
|---|---|---|
| Vicat softening temperature
@ 10N (XY) @ 10N (Z) |
DIN EN ISO 306 | 97 °C 98 °C |
| Flammability 3.0 mm | UL94 | HB |
Tolerances & accuracy
Our TPU 3D printing service has a guaranteed tolerance of >DATA-LOADING or DATA-LOADING, whichever is greater.
The table below outlines the permissible variation in dimensional accuracy for TPU 3D printing using Ultrasint™ TPU01 (MJF) technology. With its flexibility and durability, TPU01 parts offer consistent performance even in challenging applications. For further details, refer to our in-depth guide on tolerance and accuracy.
| 3D printing technology |
95% of printed parts |
Guaranteed tolerance* | Guaranteed lower limit |
Layer height |
|---|---|---|---|---|
| Multi Jet Fusion (MJF) | DATA-LOADING | DATA-LOADING | DATA-LOADING | DATA-LOADING |
| 3D printing technology | Multi Jet Fusion (MJF) |
| 95% of printed parts | DATA-LOADING |
| Guaranteed tolerance* | DATA-LOADING |
| Guaranteed lower limit | DATA-LOADING |
| Layer height | DATA-LOADING |
TPU 3D printing design guide
The Ultrasint™ TPU01 (MJF) design guide offers essential recommendations to ensure parts are optimised for TPU 3D printing. Following these guidelines closely will help achieve the best possible performance and fully utilise the material’s properties.
Wall thickness
Wall thickness influences printability and material properties: below 0.5mm won’t print, below 1.0mm may break. Walls thicker than 8mm may be hollowed out to avoid deformation during manufacturing, leaving the internal spaces full of unfused TPU powder.
Part size
Parts exceeding or falling below the specified limits are incompatible with our equipment and cannot be produced effectively.
Lattice structures
Incorporating lattice structures allows you to adjust the hardness, flexibility, and shock absorption of your part. Be sure to maintain at least a 5mm gap between the beams to prevent any unfused powder from becoming trapped inside the lattice.
Embossed detail
Embossed details are shallow raised features on your model, such as texture, patterns and text. Details smaller than 0.8mm in thickness may not be visible on your part.
Engraved detail
Engraved details are imprinted or recessed features on your model. Details must be at least 0.4mm in width and depth for clarity.
Through holes
To prevent blockages a minimum diameter of 3mm is recommended, with an increase of 2mm in diameter for every 10mm depth. (e.g., a 30mm hole should be at least 9mm wide). The TPU powder is particularly difficult to clean out of holes and cavities.
Blind holes
Blind holes are more susceptible to blockages than through holes. A minimum diameter of 4mm is recommended, with an increase of 2mm in diameter for every 10mm depth. The TPU powder is particularly difficult to clean out of holes and cavities.
Cavities
When designing hollow parts, use large openings and avoid non-line-of-sight cavities to prevent trapping unsintered material. Some unfused TPU powder may remain stuck to non-line-of-sight surfaces, including two or more openings can help reduce this.
Integrated clearance
Pre-assembled components such as hinges or interlocking parts may fuse if too close together, especially if they have thick walls.
Assembly clearance
For parts intended to be assembled post-printing. A free fit offers more space for easy assembly and movement, while a close fit is tighter and may require some force or adjustments to assemble. Due to the flexible nature of TPU it can sometimes be advised to use negative clearance, depending on part geometry.
Text size
It’s important to consider the distance between engraved letters as well as the line weight of embossed text. Any text with thickness below 0.8mm may not be visible. Unfused TPU powder tends to stick to sharp internal corners, so fillet internal edges of text with a minimum radius of 3mm to avoid this.
Large flat parts
Avoid designing large flat components as they’re particularly susceptible to deformation or warping. Adding support ribs often exacerbates deformation, so it’s best to steer clear of large flat surfaces if possible.
Wire diameter
It’s advisable to maintain a minimum thickness of 1.2mm for wires up to 7mm long, increase to 2mm for lengths up to 30mm, and use at least 3mm thickness for anything longer.
Edge thickness
To prevent damage during manufacturing, avoid designs with edges that taper to zero thickness. Thin edges are prone to damage; it’s recommended to blunt these tapered edges to a minimum thickness of 1mm.
Internal edges
TPU powder tends to stick to part surfaces, particularly in sharp internal corners or edges. To mitigate this, adding fillets is recommended, as it promotes more efficient powder removal and improves overall part quality.
The Ultrasint™ TPU01 (MJF) design guide offers essential recommendations to ensure parts are optimised for TPU 3D printing. Following these guidelines closely will help achieve the best possible performance and fully utilise the material’s properties.
Wall thickness
Wall thickness influences printability and material properties: below 0.5mm won’t print, below 1.0mm may break. Walls thicker than 8mm may be hollowed out to avoid deformation during manufacturing, leaving the internal spaces full of unfused TPU powder.
Part size
Parts exceeding or falling below the specified limits are incompatible with our equipment and cannot be produced effectively.
Lattice structures
Incorporating lattice structures allows you to adjust the hardness, flexibility, and shock absorption of your part. Be sure to maintain at least a 5mm gap between the beams to prevent any unfused powder from becoming trapped inside the lattice.
Embossed detail
Embossed details are shallow raised features on your model, such as texture, patterns and text. Details smaller than 0.8mm in thickness may not be visible on your part.
Engraved detail
Engraved details are imprinted or recessed features on your model. Details must be at least 0.4mm in width and depth for clarity.
Through holes
To prevent blockages a minimum diameter of 3mm is recommended, with an increase of 2mm in diameter for every 10mm depth. (e.g., a 30mm hole should be at least 9mm wide). The TPU powder is particularly difficult to clean out of holes and cavities.
Blind holes
Blind holes are more susceptible to blockages than through holes. A minimum diameter of 4mm is recommended, with an increase of 2mm in diameter for every 10mm depth. The TPU powder is particularly difficult to clean out of holes and cavities.
Cavities
When designing hollow parts, use large openings and avoid non-line-of-sight cavities to prevent trapping unsintered material. Some unfused TPU powder may remain stuck to non-line-of-sight surfaces, including two or more openings can help reduce this.
Integrated clearance
Pre-assembled components such as hinges or interlocking parts may fuse if too close together, especially if they have thick walls.
Assembly clearance
For parts intended to be assembled post-printing. A free fit offers more space for easy assembly and movement, while a close fit is tighter and may require some force or adjustments to assemble. Due to the flexible nature of TPU it can sometimes be advised to use negative clearance, depending on part geometry.
Text size
It’s important to consider the distance between engraved letters as well as the line weight of embossed text. Any text with thickness below 0.8mm may not be visible. Unfused TPU powder tends to stick to sharp internal corners, so fillet internal edges of text with a minimum radius of 3mm to avoid this.
Large flat parts
Avoid designing large flat components as they’re particularly susceptible to deformation or warping. Adding support ribs often exacerbates deformation, so it’s best to steer clear of large flat surfaces if possible.
Wire diameter
It’s advisable to maintain a minimum thickness of 1.2mm for wires up to 7mm long, increase to 2mm for lengths up to 30mm, and use at least 3mm thickness for anything longer.
Edge thickness
To prevent damage during manufacturing, avoid designs with edges that taper to zero thickness. Thin edges are prone to damage; it’s recommended to blunt these tapered edges to a minimum thickness of 1mm.
Internal edges
TPU powder tends to stick to part surfaces, particularly in sharp internal corners or edges. To mitigate this, adding fillets is recommended, as it promotes more efficient powder removal and improves overall part quality.
Ultrasint TPU01 (MJF) pricing
Ultrasint™ TPU01 is priced using the ‘MJF Material Pricing’ method. The 3D file’s surface is offset by 3.0 mm, and the new file’s volume is used to calculate the material cost of the part.
You can find more information on our pricing page, including tips and tricks to achieve better prices.
MJF Material Pricing
TPU 3D printing care guide
Follow this guide to help you keep your Ultrasint TPU01 (MJF) 3D prints in good condition.
Blocked powder
Due to the nature of TPU powder, it can be more challenging to fully remove from the surface and internal features of parts. Powder may easily become trapped in holes or sharp internal corners, such as engraved text. To minimise this, avoid designs with very small openings and fillet acute edges where possible. For areas where powder becomes stuck, using a pin or brush may assist in clearing these spaces.
Excess powder
With TPU 3D printing, the parts surface can retain more excess powder compared to other materials. The automated blasting process removes powder, but for any remaining residue, a thorough cleaning using a brush may be required to clear residual powder from textured surfaces.
Cleaning parts
Like any material, Flexible TPU parts may collect dirt over time. For cleaning, simply use warm water and soap. For enhanced resistance to dirt, consider options like Vapour Smoothing or Black Dye, which also provide a smoother surface and improved aesthetic.
TPU 3D printing
FAQ
How elastic is Ultrasint TPU01 compared to other materials like PA12 nylon?
TPU parts are more elastic than rigid thermoplastics like PA12 Nylon and is commonly used in applications requiring flexibility, such as wearable straps or flexible connectors. Its elastic properties make it ideal for parts that need to bend or compress without breaking, but for extreme stretch applications, TPU01 may not perform as well as softer elastomers.
Are Multi Jet Fusion TPU01 prints flexible and durable?
Yes, Ultrasint™ TPU01 prints are both flexible and highly durable, offering excellent elasticity and wear resistance. This makes them ideal for applications that require parts to absorb impact and maintain flexibility over time, such as footwear, automotive components, and protective gear.
How thick or thin can TPU01 parts be while maintaining flexibility and strength?
The thickness of TPU01 parts can vary depending on the specific application, but typically, walls as thin as 1 mm can be printed while still maintaining flexibility. For structural strength and more rigid components, thicknesses of 2–3 mm or more are generally recommended. Thinner sections will naturally be more flexible, but at very thin dimensions, parts may lose some durability, particularly if subjected to continuous mechanical stress. For load-bearing applications or where consistent performance is needed, increasing the thickness to around 3-5 mm can help strike a balance between flexibility and strength.
Designers should consider the mechanical requirements of their specific use case and experiment with wall thicknesses based on how the part will be used, as thicker sections offer greater structural integrity but reduce elasticity.
Can MJF TPU01 parts be used in outdoor applications?
Yes, TPU01 parts are UV and weather resistant, making them suitable for outdoor applications. These parts maintain their mechanical properties even after exposure to sunlight and environmental factors, ensuring long-term performance in outdoor settings.
Can MJF TPU01 parts be post-processed?
Certainly! With TPU 3D printing, parts can undergo various post-processing methods, such as vapour smoothing and dyeing, which enhance their surface quality and performance. Vapour smoothing, for example, increases elongation at break and provides a sealed surface ideal for airtight or watertight applications.
Is TPU01 resistant to chemicals and oils?
Yes, TPU01 offers excellent resistance to oils, greases, and various chemicals. This makes it well-suited for use in industrial environments where exposure to such substances is common, ensuring long-lasting performance.
What industries commonly use MJF TPU01?
TPU 3D printing with MJF is a versatile process and used across various industries, including:
- Footwear and Performance Sports: for midsoles, cushioning parts, and protective gear
- Automotive: for seals, gaskets, and flexible components
- Healthcare and Medical: for wearable medical devices and orthopaedic models
- Industrial Equipment: for protective gear and impact-resistant parts
- Aerospace and Defence: for lightweight, flexible components
- Agricultural Technology and Robotics: for flexible, impact-resistant parts used in complex machinery
Is MJF TPU01 watertight and airtight?
Yes, TPU01 can produce watertight and airtight parts with the right design. For optimal performance, it is recommended to use wall thicknesses greater than 4 mm to ensure adequate material density.
Additionally, post-processing methods like vapor smoothing can further enhance these properties by sealing the surface, reducing porosity, and improving impermeability. This makes TPU01 an excellent choice for applications requiring secure, watertight, or airtight components, such as fluid containers, seals, and protective housings.
Does TPU01 degrade over time in sunlight?
TPU01 is UV resistant and maintains its mechanical properties even with prolonged exposure to sunlight, making it an excellent choice for outdoor applications or products that will be exposed to sun and weather conditions.