• Why TPU is such a unique elastomer for 3D printing.
• The benefits of TPU, like chemical and abrasion resistance.
• Why TPU is making groundbreaking strides in applications like automotive and even footwear.
• 3D printing TPU parts with Multi Jet Fusion or Selective Laser Sintering technology.

Created in a German lab in 1937, Thermoplastic Polyurethane (TPU) is now one of those ubiquitous plastic materials that spans numerous technologies in industrial manufacturing, due to the potential for shaping the highly malleable material via a heat source into countless shapes and structures for a wide range of applications. It’s easy to understand why TPU is so popular in 3D printing as well as other traditional types of manufacturing, and why it has become an industry standard no matter the method.

Composed of segmented copolymers, TPU is unique in its chemical makeup. Exhibiting a contrasting juxtaposition in terms of its components, this elastomer features a soft segment, as well as one that is more rigid. Combined, these elements create the rubbery texture found in TPU–leading to simplicity in processing, as well as the material’s mass appeal. 

With deep roots in traditional manufacturing, designers and engineers continue to rely on this special mix of high-grade thermoplastics for methods like injection molding. Common mold designs can be used for creating parts with TPU; however, a handful of additives may be considered for better results, along with processes like drying the material beforehand, molding, and spending time in post-processing.

The Benefits—Where to Begin?

Shapeways 3D prints TPU via both Multi Jet Fusion (MJF) and Selective Laser Sintering (SLS) technologies, offering multiple benefits over other elastomers. Resistance is at the top of the list for production of durable parts meant to stand the test of time. TPU is highly resistant to impact and wear and tear, but also offers excellent abrasion-resistance–a critical property for mechanical parts that are expected to withstand years of friction as parts rub against each other during use and can begin to degrade. The ability to resist chemicals, along with oils and solvents, and harsh weather and heat, also makes TPU an excellent choice for 3D printing and subsequent industrial use.

Other great features include:

• High elongation at break – A material characteristic measured by comparing where a part breaks after being strained, versus its original length, TPU scores off the charts. Featuring exponentially higher elongation at break–or ductility–than other 3D printing materials due to its elasticity, TPU is especially useful in critical applications because it is both flexible and tough and able to handle substantial deformation to its shape without breaking.
• Superior tensile strength – Defined by how much pulling strain a part can take before fracturing, tensile strength is measured through units of pressure called megapascals (MPa). With a high tensile strength of up to 60 MPa, coupled with good flexibility, TPU can be used for high-performance parts expected to withstand rigorous use.
• Excellent load-bearing capacity – This is an important measurement as it testifies to how much weight a 3D printing material can handle before it fails. Load-bearing capacity is an extremely important factor for applications requiring high-performance products that are expected to last, including larger parts as well as smaller mechanical devices like tubing, hoses, and seals.

With the ability to print highly flexible, interlocking products as well as industrial parts on the large scale, both SLS and MJF 3D printing offer greater design freedom too. This is mainly due to a sophisticated system that eliminates the need for supports during 3D printing, meaning that designers aren’t restricted by the worry of figuring in complex support structures.

3D Printing TPU with Multi Jet Fusion Technology

Shapeways offers Multi Jet Fusion (MJF) for 3D printing Ultrasint® TPU 01, resulting in prototypes and parts that are robust, with strong mechanical properties. Like SLS 3D printing, MJF is powder-based; however, it does not rely on laser heat to melt layers together. Instead, one layer of powder is deposited after the other, 80 microns at a time, with an inkjet array moving back and forth jetting out fusing agents to fuse the powder particles together, and detailing agents to assure good detail and smooth surface texture. 

As the layers melt together quickly via thermal heat with MJF 3D printing, resulting parts are stable and well-defined. A standalone cooling system also helps eliminate challenges like warping, shrinkage, or overall failure in parts. 

Design Guidelines

For this material, 3D models must be within the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • At least 1 extant dimension over 19mm
• Bounding Box Max
  • 284 × 380 × 380mm 

This 3D printing material is available in a gray, natural finish. Explore the design guidelines for TPU further here.

3D Printing TPU with Selective Laser Sintering Technology

Featuring power and speed, SLS 3D printing technology makes it possible for Shapeways to 3D print highly accurate TPU parts that are detailed, with smooth surfaces. One of the oldest 3D printing technologies–aside from SLA 3D printing–SLS is a subcategory of powder-bed fusion and heavily relied on for both rapid prototypes and highly functional end parts. 

The process is set into motion as a small amount of powder is dispersed onto the SLS print bed. A high-powered laser traces the shape of the 3D design into the powder as each layer is 3D printed and fused together at a high temperature just below the melting point.

Design Guidelines

For this material, 3D models must be within the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • 15 x 15 x 0.7 mm
  • X + Y + Z ≥ 15.0 mm
• Bounding Box Max
  • 200 x 200 x 200 mm

This 3D printing material is available in white, with a Standard matte finish. Explore the design guidelines for 3D printing TPU with SLS technology further here.

Typical Applications for Thermoplastic Polyurethane

Automotive

While the automotive industry has been using 3D printing for decades in prototyping, as well as functional parts for both the interiors and exteriors of vehicles, TPU allows for the design of truly personalized components, allowing for consumer-specific comforts. While such options may become much more detailed in the future, today’s manufacturers are hard at work not only using additive manufacturing for critical components but also in focusing on the drivers themselves and developing new luxuries like customized headrests and seats. TPU is often chosen for these parts because of its versatility in terms of softness for one part, yet hardness and functionality for another. There are a variety of different finishes available too for automotive applications.

Consumer accessories  

The 3D printing industry is well known for expanding options to consumers in the area of accessories, mainly due to the enormous potential offered by expanded design freedom and the ability to customize. This is especially true for items like smartphone cases, allowing customers to completely personalize an item, adding exciting and unique touches to a product that is pretty much impossible for most people to live without today. Not only that, these items are durable enough to last for years. TPU is also an excellent choice for adding quality and customization to highly functional items like soft grip systems and rubber mats.

Footwear

3D printing has made a powerful impact within the footwear industry, and on multiple levels. Designers working from their studios or homes are able to make creative new eco-friendly designs on demand and send them to Shapeways for 3D printing services. Large corporations are using materials like TPU to max out designs for epic, futuristic looking running shoes with a range of features meant to propel athletes and everyday wearers forward in terms of comfort and stamina.

There is also the potential for incredibly personalized fit in shoes, beginning with insoles that can be 3D printed to encourage better support and balanced gait, as well as orthotics that can be made to fit and re-sized easily as needed. With rapid production in 3D printing, more durable footwear products can be made that are also more flexible, and lighter in weight. 3D scanning plays a role for much of the footwear industry as the wearer’s measurements can be scanned quickly, making unprecedented strides in comfort, rather than expecting someone to fit into a typical size, or somewhere in between.

Medical devices

Another area where 3D printing is offering enormous impact, TPU is behind the production of numerous medical devices bearing complex, lightweight geometries that may not have been possible before with traditional manufacturing. Products like braces, prosthetics, and implants can be 3D printed after 3D scans are taken from patients, offering them safe, customized devices that are able to stand up to long-term daily use without causing skin irritation. For children wearing prosthetics or orthotics this is an incredible boon, with fittings taking a fraction of the time and without discomfort. While such devices may have taken weeks or even months to arrive previously, at great expense, now they can be made quickly–and changes can be made to designs quickly also.

Robotics

TPU is also suitable for robotics, and especially softer applications which may require extremely flexible parts like connectors, actuators, and simulated fingers, arms, and flex grippers for performing tasks whether on a manufacturing production line or at the individual level. This material can also be used for tires and other accessories attached to moving robots, as well as those that may be performing 3D printing activities on their own.

Sports gear

Because of the protective nature of sports gear, 3D printing technology with TPU is able to play a very important role in helping to prevent injuries in players. Using lattice structures for interior strength and incredible absorption on impact, 3D printed protective gear may include helmets, guards, and more, all with the potential to be heavily customized for the comfort and safety of the athlete.

Ideas for 3D Printing with TPU? Get Started Now

For faster turnaround time and highly customized, production runs at any volume, contact Shapeways to learn more about on-demand 3D printing. Allowing manufacturers to keep a digital inventory of their stock or spare parts, on-demand printing means decreasing or saying goodbye to warehouse space altogether. 

Upload your design now to get started in 3D printing with TPU.

About Shapeways

Enjoy the benefits of this advanced technology and a wide range of materials from Shapeways for 3D printing your creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to 3D print over 21 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here. 

The post A Comprehensive Guide to Industrial 3D Printing with Thermoplastic Polyurethane (TPU) appeared first on Shapeways Blog.

In a recent webinar co-presented with Shapeways, BASF powder bed fusion products were the topic at hand. Automotive was also at the forefront of the discussion, as one of the first industries to embrace 3D printing technology, far before most people knew what it was—or what it had the potential to do in the long run. 

Automotive Manufacturers Still Top the List for 3D Printing

As 3D printing hit the mainstream in the past decade, only then did the average lay person realize that large automotive companies with vast resources had quietly been using the technology for many years. Today, automotive 3D printing tops the list in terms of industrial users, with the vast number of products still being made for prototypes and proof of concept or test models, as well as mechanical and spare parts.

Working from three different application technology centers—in Heidelberg, Shanghai, and Detroit—the Forward AM team is able to focus on bringing new material products to the automotive industry, which means Shapeways customers are able to access additive manufacturing solutions specific to their designs, whether they are still engaged in product development or moving forward in manufacturing end-use parts for automotive applications.

Open Additive Manufacturing Systems Are Encouraged

Compatibility between 3D printing materials and technology is key to ensuring printability, and ultimately, quality parts. Open additive manufacturing systems also promote greater openness to innovation, and allow manufacturers to use all the different materials available for smaller and large-scale 3D printing; however, these processes are contingent on printer specifications meeting printer requirements of any given material so that it can be directly processed.

In developing TPU for use with HP’s MJF 3D printing systems, BASF Forward AM took four and a half years to sample and test the materials.

“BASF works with manufacturers to make sure that materials and machine combinations are the best they can be,” said Jeremy Vos, Business Development Manager at BASF Forward AM in North America. “We don’t participate right now with any types of additive manufacturing that have closed systems.”

3D Printing in Automotive–There’s No Reason to Wait Anymore

Many traditional manufacturers are still looking into the technology wondering about the possibilities for their own companies over time, and in many cases procrastinating due to a bevy of concerns about how to integrate such processes.

“Ford used to always talk about ‘now, near, and far,’” said Vos. “This is kind of that same idea. What’s now? What’s near, what’s far? The difference is that we don’t have any far on here.”

“Our photopolymers are the materials growing the fastest right now, as far as technological advancements go. We’ve got all kinds of opportunities for prototyping, for replacement parts, and even for tooling applications where we can use compatible materials to add in assembly.”

BASF Forward AM 3D Printing Materials and Technology

Nylon 6 Mineral Filled (PA6MF)  

Available in black, Nylon 6 Mineral Filled (PA6MF) is a highly adaptable material, and well-suited for 3D printing as it allows for a transition from metal or alloys to more economical and versatile polymers. Used in highly industrial applications, PA6MF offers the following benefits:

• High stiffness
• Strength
• Impact resistance
• Heat stability
• Mineral-filled reinforcements offering properties similar to injection molded parts

PA6 MF is an excellent choice for prototypes of final series parts that require extensive testing for fit and performance. This is especially true in the automotive industry for engine parts, structural parts, and prototypes that must be functional too.

Selective Laser Sintering with PA6MF

Shapeways 3D prints PA6MF using Selective Laser Sintering (SLS) technology, another very powerful form of powder-based 3D printing. In this case, lasers are used to cure powder once it is dispersed on the print bed. A computer-controlled C02 laser traces a cross-section of the design in the powder, scans it, and then is responsible for melting all the powder particles together just under the melting point.

SLS 3D printing is also a technology offering greater latitude in design because supports are unnecessary. Up to a thousand parts may be included in one build, yielding high accuracy and repeatability, every single time for 3D printing in automotive.

Explore the guidelines for this material further here.

Polypropylene (PP) 

Polypropylene (PP) is another versatile material ideal for automotive parts. With its excellent chemical resistance, low moisture absorption and long-term durability, HP High Reusability PP enabled by BASF is ideal for production of 3D printed automotive prototypes and final parts offering the same properties as PP for injection molding.

Shapeways also recommends PP, available in gray with a natural finish, for testing complex structures. Its genuine PP makeup allows for prototyping and evaluation of parts in critical areas like automotive, where traditionally manufactured PP is used. 

PP allows for speed and efficiency in manufacturing, machining and tooling can be eliminated, and it is easy to make changes to industrial parts. 

Other benefits include:

• Excellent chemical resistance
• The ability to weld with injection molded PP
• Low moisture absorption
• Biocompatibility—meets ISO 10993 and US FDA Intact Skin Surface Devices Statements

Multi Jet Fusion with PP

Shapeways relies on Multi Jet Fusion (MJF) to 3D print PP, harnessing the power of HP’s fast technology, which is also capable of enormous output in production.

Recommended for applications requiring tough parts and complex geometries, MJF begins like most other powder-based technologies: a layer of powder is spread onto the print area, and then particles are melted together. The difference with MJF is that lasers are not used; instead, a detailing agent is used to evaporate and cool the printing area, fusing the layers together with uniform strength. 

Supports are not necessary, due to the bolstering effect of unsintered powder during the printing process, leading to greater design freedom—along with ease in post-processing and the elimination of the potential for damage in removing supports at the end.

Explore the guidelines for this material further here.

Thermoplastic Polyurethane 

Shapeways offers Ultrasint TPU01 material from BASF, available in gray, also using Multi Jet Fusion 3D printers. These materials offer multiple benefits over other elastomers, to include:

• Superior tensile strength
• High elongation at break due to elasticity
• Excellent load-bearing capacity  
• Resistance to chemicals, oil and grease, harsh weather, heat, and abrasion

Explore the guidelines for this material further here.

About Shapeways

Contact Shapeways now to enjoy the benefits of advanced technology and materials for 3D printing with accuracy, complex detail, and no limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to make over 21 million parts! Read case studies, find out more about Shapeways solutions, and get instant quotes here.

The post Excellence for Automotive: 3D Printing Materials from BASF appeared first on Shapeways Blog.

The Advantages—Where to Begin?

Shapeways offers TPU in off-white for use with Selective Laser Sintering (SLS), using EOS 3D printers, as well as Ultrasint TPU01 material from BASF, available in gray, using Multi Jet Fusion 3D printers. These materials offer multiple benefits over other elastomers, to include:

• Superior tensile strength – Defined by how much strain a part can take before fracturing, tensile strength is measured through units of pressure called megapascals (MPa). With a high tensile strength of up to 60 MPa, coupled with good flexibility, TPU can be used for high-performance parts that must stand up to rigorous use.
•  Elongation at break – This material characteristic is tested by comparing where a part breaks after being strained, versus its original length. TPU is known for high elongation at break due to its elasticity, making it especially useful in critical applications because it is also so tough.
• Excellent load-bearing capacity – This is an important measurement as it testifies to how much weight a 3D printing material can handle—a factor that could be extremely important in applications requiring high-performance products that are expected to last, including mechanical devices like tubing, hoses, and seals.
• Resistance – TPU is able to stand up to many different factors because of its natural resistance, which is why it is considered such a multi-purpose 3D printing material. This includes resistance to chemicals, oil and grease, harsh weather, heat, and abrasion.

Typical Applications for Thermoplastic Polyurethane

Automotive

While the automotive industry has been using 3D printing for decades in prototyping, as well as functional parts for both the interiors and exteriors of vehicles, TPU allows for the design of components that focus on greater comfort for the driver, like customized headrests and seats. With TPU, textures may range from soft and luxurious, to rigid and functional, depending on the interior part for a vehicle. There are a variety of different finishes available too for automotive applications.

Consumer accessories  

The 3D printing industry is well known for expanding options to consumers in the area of accessories, mainly due to the enormous potential offered by expanded design freedom and the ability to customize. This is especially true for items like smartphone cases, allowing customers to completely personalize an item, adding exciting and unique touches to an item that is pretty much impossible to live without. TPU is also an excellent choice for adding quality and customization to highly functional items used daily like rubber mats and products like handles.

Footwear

3D printing has made a powerful impact within the footwear industry, and on multiple levels. Designers working from their studios or homes are able to make creative new eco-friendly designs on demand and send them to Shapeways for 3D printing services. Large corporations are using materials like TPU to max out designs for epic, futuristic looking running shoes with a range of features meant to propel athletes and everyday wearers forward in terms of comfort and stamina.

There is also the potential for incredibly personalized fit in shoes, beginning with insoles that can be 3D printed to encourage better support and balanced gait, as well as orthotics that can be made to fit and re-sized easily as needed. With rapid production in 3D printing, more durable footwear products can be made that are also more flexible, and lighter in weight.

Medical devices

Another area where 3D printing is offering enormous impact, TPU is behind the production of numerous medical devices bearing complex, lightweight geometries that may not have been possible before with traditional manufacturing. Products like braces, prosthetics, and implants can be 3D printed, offering patients safe, customized devices that are able to stand up to long-term daily use without causing skin irritation.

Robotics

TPU is also suitable for robotics, and especially softer applications which may require extremely flexible parts like connectors, actuators, and simulated fingers, arms, and flex grippers for performing tasks whether on a manufacturing production line or at the individual level. This material can also be used for tires and other accessories attached to moving robots, as well as those that may be performing 3D printing activities on their own.

Sports gear

Because of the protective nature of sports gear, 3D printing technology with TPU is able to play a very important role in helping to prevent injuries in players. Using lattice structures for interior strength, 3D printed protective gear may include helmets, guards, and more, all with the potential to be heavily customized for the comfort and safety of the athlete.

Get Started with TPU Now

Upload your 3D models now to get started with printing in TPU using industrial SLS technology or in Ultrasint TPU01 using MJF technology.

The post Thermoplastic Polyurethane (TPU): Highly Versatile for Many 3D Printing Applications appeared first on Shapeways Blog.

Recognized for accuracy and repeatability in industrial parts with excellent mechanical properties,

SLS 3D printing has continued to evolve–remaining at the top of the additive manufacturing hierarchy due to its sheer power–and versatility. 

What is SLS?

To define Selective Laser Sintering means understanding industrial 3D printing. Serving as a subcategory of powder-bed fusion, SLS 3D printing relies on a laser to trace the cross-section of each 3D design into the material dispersed onto the print bed, and sintered just under the melting point. Once the desired structure is complete, parts are cooled in the build chamber to avoid warpage and preserve integrity of the prints. After, they are removed for post-processing, to include removal of excess powder and then on to finishing, to include dyeing, vapor smoothing, polishing, and more.

SLS industrial 3D printers are capable of producing large parts, in large volumes. While smaller printers may range in build volume from 200 mm x 250 mm x 330 mm, larger laser 3D printers may range in size from 650 mm x 350 mm x 550 mm to 700 mm x 380 mm x 580 mm, with a layer thickness of 100 to 120 microns. These SLS printers are remarkable in that hundreds or even thousands of parts can be 3D printed at one time.

SLS Benefits: Expanding Design Freedom and Production Volume 

Support structures are not required for SLS 3D printing, leading to unique advantages for this technology as well as Multi Jet Fusion (MJF) 3D printing. Unsintered powder bunches around parts as they are 3D printed, stabilizing structures, and eliminating the need for support structures. This leads to much greater design freedom as designers are able to engineer parts without having to compensate for intricate supports. No requirements for supports means less use of materials, reducing the potential for damage in post-processing, and eliminating the need for repeated 3D printing.

Shapeways engineers are able to optimize nesting of parts due to the lack of requirement for intricate support structures that would make smart packing impossible. Smart packing is key to optimization, allowing for parts to be placed correctly and keep machines in good working order by running them consistently with maximum builds for efficiency. Streamlined, dense packing of parts reduces the height of the build platform and saves materials.

“The 3D printing nesting software does the hard thinking for us in terms of whether or not a part fits into the spaces available in a build tray,” said Zach Dillon, User Application Team Lead at Shapeways.

Because of the ability to nest so many 3D printed parts together, Shapeways customers experience a key  advantage of 3D printing: speed in turnaround. Numerous projects can be completed simultaneously, and SLS 3D printing powder is easily recycled, promoting sustainability in additive manufacturing with each job.  

When Shapeways customers print in large volumes, being able to work directly with the User Application team to optimize every aspect of production is a huge benefit. 

“We have to take everything into consideration from how larger 3D printed parts will affect others around them to how they will all be unpacked and cleaned in post-processing,” said Dillon.

SLS 3D Printing Materials

Nylon 11 [PA11(SLS)]

Nylon 11 [PA11(SLS)] is a robust white polyamide offering great tensile strength, durability, impact resistance, and flexibility. Due to its biocompatibility, Nylon 11 [PA11(SLS)] is uniquely suited for manufacturing the following:

• Exterior medical devices
• Automotive parts
• Sports equipment
• Loaded functional prototypes
• Hinges

Explore the design guidelines for Nylon 11 [PA11(SLS)] here.

Nylon 12 [Versatile Plastic]

Nylon 12 [Versatile Plastic] is a strong polyamide relied on worldwide for industrial products. This material lives up to its name, set apart from other 3D printing materials mainly due to high ductility. This refers to the material’s flexibility for thinner structures and moving mechanical parts, but stiffness for substantial, end-use parts. Nylon 12 [Versatile Plastic] is dishwasher safe, heatproof to 163C/325F, skin-friendly, and offers good chemical resistance.

Typical applications include:

• Architecture, to include interior statement pieces
• Automotive
• Drone technology
• Footwear, fashion, and accessories
• Luxury jewelry
• Mechanical components, including interlocking parts
• Medical models
• Robotics

Colors and finishes available for Nylon 12 [Versatile Plastic]:

• Natural: This finish has a slightly rough surface and a matte finish.
• Processed: This finish removes some material to create a smoother surface.
• Premium: Relying on ceramic media tumbling, this finish removes material to create a smooth surface.
• Smooth: This finish has a smooth surface and slight shine, created using a physio-chemical process with vapor.
• Colors: Versatile Plastic is naturally white. Shapeways also offers Black, Pink, Red, Orange, Yellow, Green, Blue, and Purple. Colors other than White are dyed and will wear through over time with handling.

Explore the guidelines for Nylon 12 [Versatile Plastic] 3D printing material here.

Polypropylene

Polypropylene is a versatile material offering excellence in mechanical properties, to include durability and high elongation at break. Highly suited for rapid prototyping as well as additive manufacturing of elastic, end-use products, PP is used for important applications like:

• Automotive
• Consumer products
• Electrical casings
• Medical devices
• Toolmaking

This material is available in a slightly translucent off-white, featuring a matte surface.

Explore the design guidelines for Polypropylene here.

Thermoplastic Polyurethane (TPU)

Thermoplastic Polyurethane (TPU) is a rubber-like material (available in white) that offers impact resistance and durability, and works well for 3D printing of interlocking parts. Made for elastic, end-use products, TPU is used for important applications like:

• Automotive
• Medical devices
• Robotics
• Footwear
• Sports equipment

This material is available in standard, featuring a slightly rough surface with a matte finish.

Explore the design guidelines for Thermoplastic Polyurethane (TPU) here.

Customers and Applications:

At Shapeways, SLS 3D printing has revealed itself to be both popular and versatile, whether customers are designing for aerospace and drone technology, architecture, luxury jewelry, or medical models. SLS 3D printing is a stand-out technology for designers and engineers making rapid prototypes or high-performance, functional parts.  

Aerospace

The aerospace industry is a leader in its use of 3D printed parts, allowing engineers to create innovative designs and use lightweight, durable materials with complex geometries. This is especially true for companies like Munich-based Quantum-Systems, specializing in advanced eVTOL (electric vertical take-off and landing) drones. 

Using SLS 3D printing for prototyping and manufacturing of functional parts, Quantum Systems is able to make lightweight parts, while taking advantage of “synergy effects” in reducing part counts and assembly.

“Only because of the fact that we have integrated this manufacturing method into our manufacturing and development process, have we been able to significantly reduce development time. For injection molded parts, we save around 10 weeks by using 3D printed samples to release the CAD data,” said Florian Seibel, CEO of Quantum-Systems.

“The probability that these parts need a second loop of corrections is quite low in this way. For CNC-manufactured parts it is the same. We often just skip the first round of samples with SLS 3D printed parts, which saves us three to four weeks. In general, I would say 3D printing saves us 20 to 50 percent of time, depending on which parts we design.”

Architecture

Verner Architects designed a six-foot bathroom vanity for a luxury remodel on a home in California. Verner worked with Shapeways to 3D print the interior statement piece ensuring that durability and water resistance were top of mind.

Due to the print-bed size of SLS technology that Shapeways offers, the architects at Verner were ‘pleasantly surprised’ at the easy assembly of the six-foot-long vanity. 3D printed with Nylon 12 [Versatile Plastic], the 3D printed statement piece was also coated with polyurethane for waterproofing. Two test prints were performed in-house at Verner Architects, allowing the team to refine the design and final structure.

Luxury Jewelry

Industrial designers and luxury jewelry makers like Groen and Boothman use Shapeways services for rapid prototyping and 3D printing the final parts for luxury jewelry like their custom Creatures design series, featuring unique cuff bracelets. The designers rely on the lightweight quality of Nylon 12 [Versatile Plastic], along with the strength and durability of the material.

“3D printing gives us a chance to explore new avenues and get away from the mass production paradigm,” said Joanna Boothman.

Medical

Uruguay-based Armor Bionics creates intricate 3D designs for medical models that are 3D printed by Shapeways via SLS technology. Surgeons rely on the complex 3D printed medical models for more in-depth diagnosis, training, and treatment. Armor Bionics CEO Bruno Demuro is dedicated to offering medical professionals better solutions for surgical planning:

“We’ve seen the benefits and how much treatment affects the patients,” said Demuro. “It betters the outcome of every single surgery where it is applied.”

Other industrial design firms like Flamingo Works collaborated with Shapeways to 3D print colorful simulators using SLS 3D printing materials like Nylon 12 [Versatile Plastic] to train surgeons in robot-assisted surgeries. Yonatan Assouline, Manager and Co-founder, points out that while 3D printed games designed for learning may look simple, the tasks require practice, medical training, and concentration to excel. This is especially true for surgeons training with robotic grips that shift both forward and reverse to reach objects and complete exercises.

“The training for this technique and the framing of the technology was completely unknown at first,” explained Naty Moskovich, Chief Designer and Co-founder of Flamingo Works. “We were developing 50 to 60 learning tasks at a time, coming up with all sorts of different ideas, and sending them to physicians to see if they liked them or not. 

“We would develop one skill and remove another while prototyping. 3D printing with Shapeways gave us the freedom to try out endless new ideas during the product development phase.”

About Shapeways

Enjoy the benefits of this advanced technology and a wide range of materials from Shapeways for 3D printing your creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to 3D print over 21 million parts! Read about case studies, find out more about Shapeways additive manufacturing solutions, and get instant quotes here.

The post An Expert Guide to SLS 3D Printing appeared first on Shapeways Blog.