Commercial Applications for 3D-Printed Elastomers
Author: John Schober, Market Development Lead
Close-up of 3D-printed components on a dress
Today’s $250-million market for 3D-printed elastomers represents only a small fraction of the $90-billion global elastomer market.
But that is changing. Rubber manufacturers and OEMs that use or produce elastomers are starting to explore 3D printing for a range of applications spanning industrial and consumer goods. From prototypes to finished components and aftermarket parts, the elastomers industry is getting on board with additive manufacturing.
What is causing this shift? First, 3D printing of elastomers can offer advantages over traditional manufacturing methods like injection molding, just as with rigid plastics. It can drive efficiency and cost savings, reduce material waste, simplify complex supply chains, and increase reliability — all of which deliver a competitive advantage. Second, the technology for printing elastomers has significantly improved in recent years and new materials are becoming available. In this article, we explore examples of 3D printing with elastomers.
Prototyping
Prototyping is still the most common use case for 3D printing across all materials and this is no different for elastomers. For businesses that regularly design and develop new products, 3D printing prototypes in-house provides a fast, low-cost solution. It’s an easy way to make prototypes that demonstrate specific features both for internal evaluation and with customers.
With elastomeric products, one of the most important features to demonstrate is the flexibility of the part. Prototypes that can demonstrate both durability and flexibility can be powerful tools for working with customers. A few years ago, it wasn’t possible to print elastomers that showcased the right levels of durability and flexibility, but new 3D printing technologies (e.g., reactive extrusion additive manufacturing) have made it possible to print impressive prototypes that meet specifications.
It’s not just rubber manufacturers and OEMs getting in on the action. Design and prototyping houses that offer development services also use 3D printing to make prototypes. Traditionally, these service providers would build molds and cast parts from silicones or urethanes. As the technology for 3D printing elastomers has developed, they have been converting to 3D printing prototypes with silicones, photopolymers, and thermoset polyurethanes (TPUs). Perhaps even more than OEMs, prototyping houses compete on cost and delivery time. 3D printing allows them to turn projects around more quickly and affordably thanks to reduced tooling costs, less material waste, faster design iterations, and shorter lead times.
Finished goods
Additive manufacturing is also useful for producing finished goods and components. A number of sectors are embracing 3D-printed elastomers for everything from automotive applications to apparel and medical devices to military uses.
Footwear is especially known for “flirting with 3D printing for years”, as highlighted by Carolyn Schwaar in a recent article for Forbes. According to Schwaar, it seems like footwear companies that used to consider the technology a way to produce small quantities of novelty products, are now considering the potential benefits of 3D printing at scale.
“With an increased focus on simplifying supply chains and boosting the footwear industry’s sustainability profile, brands see 3D printing as a match for both. ”
Soles are the primary components of the shoe for which 3D printed elastomers are being considered due to the need for flexibility and durability, and low weight, but some are looking at entire shoes.
Another industry that has embraced 3D-printed elastomers is the medical device industry. Silicones and TPUs are commonly used in medical devices in large part because they are biocompatible, non-irritating, and soft to the touch. A paper recently published by researchers at the Technical University of Denmark, also notes the potential for printed elastomers to “mimic soft tissue”.
Prosthetics, hearing aids, dental retainers are the devices that have gotten the most traction and publicity. Other applications include implants and surgical instruments. The researchers note that the unique properties of polyurethane “makes it suitable for healthcare applications such as self-tightening sutures, sensors, and wearable electronics.”
Beyond material properties, 3D printing offers a high degree of customization at a comparatively low cost and enables features that are difficult to produce with conventional manufacturing methods. Healthcare is personal, and as the medical device industry increasingly seeks personalized solutions, 3D printing is well-positioned to help meet that need.
Aftermarket parts
Aftermarket parts have long been touted as an attractive application for 3D printing. The technology offers the prospect of lowering the cost and reducing supply chain complexity for the wide range of designs that are needed for service industries such as industrial equipment, agricultural equipment, aerospace and defense, and even automotive.
Until recently, 3D-printed elastomers were not adequate. Additive manufacturing seemed to be limited to DIY 3D-printed parts for home repairs. Now, however, higher quality 3D-printed thermoset polyurethanes (in demanding industrial applications) and TPU’s/TPE’s, (in less demanding industrial applications) are changing that as the cost and durability of parts made from these materials are increasingly sufficient.
3D-printed grommets for automotive aftermarket
3D-printed elastomers are still not as widely used in commercial applications as plastics, but they are likely to grow in the coming years. Especially for low- to medium-volume runs, the technology offers a cost-efficient way to meet demand while reducing overstock, obsolescence, and waste.
Did you find this article helpful? Stay tuned for our next article on emerging applications and the economics of 3D-printed elastomers.