3D printing is making a dramatic impact on people’s lives. The patient of a client manufacturing custom prosthetics with ABCorp 3D recently got the “perfect fit” for his lower limb. This tailored fit was 20 years in the making and created through a combination of digital scanning, CAD, and 3D printing.
3D printing, also called additive manufacturing, is expanding into markets that are new and labor intensive like prosthetics. As 3D printing processes and materials evolve, this expansion delivers life-changing benefits that are challenging to mirror with traditional manufacturing.
HP’s Multi Jet Fusion (MJF) process makes this possible by printing with a wide variety of materials designed for specific applications. The 3D printing material that gave this client the “perfect fit” is Ultrasint® TPU01.
What is Ultrasint® TPU01?
Thermoplastic Polyurethane (TPU) is an elastic and flexible material that is durable, strong, and smooth to the touch. It features high wear resistance and withstands environmental exposure to oils, grease, and solvents. Ultrasint TPU01 adds superior resistance to high and low temperatures, making it a dependable substitute for hard rubber parts.
Ultrasint TPU01 is ideal for 3D printing:
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- Sports equipment
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- Automotive parts
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- Chaussures
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- Cas électroniques
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- Industrial tools and fixtures
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- Orthotics and Prosthetics (O&P) and other medical applications
Each of these applications requires unique materials and finishes. Ultrasint TPU01 plus post-processing can bring parts to market faster and with similar characteristics to traditionally manufactured parts.
Post-processing options for Ultrasint TPU01
Several post-processing applications are available for Ultrasint TPU01, and ABCorp 3D currently offers dyeing and vapor smoothing. Ultrasint TPU01 is grey in color when printed via MJF. Dyeing the part gives it a uniform black color that penetrates the surface.
An MJF-printed part will change from grey to black when vapor smoothed as a surface treatment. Dyed parts will have a part finish with an average surface roughness (Ra) of around 1.18. This effectively seals the part from exposure to moisture and air, improving bacteria protection.
Another popular post-processing option for 3D printed parts are ceramic coatings such as Cerakote and Durakote.
Latticing avec Ultrasint TPU01
Lattice structures are found throughout nature and often mimicked by the structural foam industry. Incorporating lattice design into MJF 3D printing gives parts an additional dimension of performance properties. It’s possible to print lattice structures into different areas of the part, providing extra flexibility and customization. Latticing of MJF printed TPU parts is popular in the sports, O&P, and automotive industries.
An article in Magazine AM a discuté de la manière dont le treillis ainsi que le matériau TPU peuvent être utilisés to better fit a sports helmet to the wearer’s head. The article notes, “Meanwhile, padding made via 3D printing in this way can also be customized to the wearer by designing from a scan of the head. We experienced this with digital-material helmet padding made from our personal scan data.”
In the O&P field, we see parts with custom lattice structures tailored to different parts of the prosthetic, providing a better fit and happier client. Just ask the guy that finally found the best prosthetic fit after 20 years!
“Il était très enthousiaste à ce sujet. Il est heureux de voir que nous l'avons enfin mis en condition pour qu'il puisse se passer totalement de plâtre - cela fait 20 ans qu'il travaille dans ce sens”.
Let’s talk about your 3D printing needs
ABCorp is a secure contract manufacturer with a legacy dating back to 1795. We are now a leading manufacturer of secure payment cards, commercial cards, and secure identification credentials. During COVID, we ventured into 3D printing to manufacture PPE and address tightening supply chain concerns.
ABCorp 3D now houses multiple HP MJF 580 and 5210 series printers in our secure printing facilities. Our current material offerings are Nylon PA-11, PA-12, Polypropylene and flexible TPU. The HP 580 creates colors parts in Nylon PA-12CB material.
Si vous êtes en mesure d'examiner vos pièces en vue d'un inventaire numérique ou si vous souhaitez que nous imprimions quelques pièces, n'hésitez pas à nous contacter. Un fichier CAO avec un fichier .stl ou 3MF ainsi que des spécifications de conception suffisent pour entamer la conversation.
