TPU 3D printing — flexible material for gaskets and industrial parts

TPU material is the answer when your design needs something that can both bend and hold up. As one of the most widely used technical FDM filaments in industry, TPU combines the flexibility of rubber with the precision of plastic — and at Maker Factory we can print complex TPU parts with tolerances down to ±0.3 mm and deliver them within a few business days.

On this page we cover when TPU is the right choice, which TPU variants we work with, and what it typically costs to have flexible industrial parts printed with us.

Read more about our broader 3D printing service or go directly to our TPU 95A material page and TPU 65D material page for technical specifications.

What is TPU material?

TPU material (thermoplastic polyurethane) is an elastic plastic type that combines the properties of rubber and thermoplastic. The material can be deformed repeatedly without losing its shape, withstands impact and vibration well, and is chemically resistant to oil, grease and many solvents.

In FDM 3D printing, TPU is used as a 1.75 mm diameter filament. The print process requires a well-tuned extruder and lower print speed than standard PLA or PETG, but in return it gives access to a material class that injection molding is normally the only solution for. With TPU 3D printing you can produce one piece or a hundred — with the same setup and no tooling cost.

Shore hardness is the key parameter to know. The lower the Shore A rating, the softer and more flexible the material. TPU 95A is noticeably softer than TPU 65D, which approaches a semi-rigid plastic material with some flex.

When do you choose TPU over other materials?

TPU isn't the universal answer to every printing job — but it's the obvious choice in specific situations. Here are the three scenarios where we consistently recommend TPU over PETG, PLA or PA6-CF:

Seals and gaskets — fast replacement of discontinued parts

Machine manufacturers and production companies regularly run into situations where a gasket or seal has been discontinued by the supplier — or simply has a 6-12 week lead time. With a CAD file or a measurement from the original part, we can print a functional TPU replacement within 2-3 business days.

TPU withstands repeated compression and returns to its original shape, making it well suited as a sealing material in non-critical pneumatic and hydraulic systems. The material is chemically resistant to most industrial lubricants and oils, and can be printed with infill and wall thickness tuned to the desired compression level.

Shock absorbers and vibration isolators in industry

Vibration from motors, pumps and conveyor belts shortens the lifespan of nearby components and creates noise problems. This is traditionally solved with molded rubber parts — but tooling costs are high and lead times long, especially for non-standard geometries.

3D-printed TPU shock absorbers solve this by giving full design freedom. We can print complex geometries with varying wall thickness that deliver exactly the stiffness and damping the job requires. Gyroid and honeycomb infill structures are used to tune the mechanical response without changing the outer dimensions.

Flexible prototypes and functional parts for testing and validation

When a new product needs to be validated — and final production is planned in molded rubber or silicone — a 3D-printed TPU part is the fastest and cheapest step to confirm design and fit. TPU prototypes give a realistic impression of the material's behavior in use, and any design changes can be implemented overnight.

We've helped companies in medical devices, toy design and industrial design validate flexible components in TPU before investing in expensive tooling or molding processes.

TPU 95A and TPU 65D — difference and choice

At Maker Factory we work with two TPU variants with different Shore hardness. The choice between them depends on how soft or rigid the finished part needs to be.

As a rule of thumb: choose TPU 95A for anything that needs to feel soft and flexible — gaskets, seals, grip covers and shock absorbers. Choose TPU 65D when you need some rigidity combined with flex.

Comparison: TPU vs. PETG, PA6-CF and PLA

Typical jobs we solve with TPU 3D printing

• Replacement gaskets and seals for manufacturing companies — especially for discontinued or custom-sized parts
• Shock absorbers and vibration isolators for machines, pumps and motors
• Grip covers and anti-slip surfaces for hand tools, medical equipment and consumer electronics
• Flexible hoses and cable glands for electronics and technology applications
• Protective sleeves and bumpers for equipment exposed to impact and drops
• Wheels and rollers for carts — TPU 65D offers good wear resistance and damping
• Prototyping rubber parts for validation before investing in molding

What does TPU 3D printing cost at Maker Factory?

The price mainly depends on the part's volume, weight, print time and any post-processing. TPU requires a slower print speed than PLA and PETG to ensure consistent quality.

• Smaller parts (under 50 cm³) — typically DKK 150-400 per piece
• Medium parts (50-200 cm³) — typically DKK 300-900 per piece
• Batches (10+ pieces) — volume discount applies from 5 pieces

FAQ about TPU 3D printing

Is TPU the same as rubber?

TPU behaves similarly to rubber — it's flexible, elastic and withstands repeated deformation. But TPU is a thermoplastic, not vulcanized rubber. It can be melted and reused, and it's printed with FDM technology. For most industrial replacement purposes, TPU works as a practical alternative to molded rubber.

Can TPU-printed parts be used in wet environments?

Yes. TPU has good water resistance and isn't hygroscopic in use. Parts printed in TPU can be used in damp environments and exposed to weak acids and bases. They shouldn't be used in contact with strong solvents or at temperatures continuously above 80-90°C.

What is Shore hardness, and which should I choose?

Shore hardness is a scale for material softness. TPU 95A is noticeably softer than a rubber sole, while TPU 65D approaches a hard plastic-rubber. Choose 95A for gaskets and grip parts, 65D when you need more structural stability while retaining flex.

Can TPU-printed parts be post-processed?

TPU is harder to post-process than PLA and PETG. It can be painted with flexible coatings designed for rubber and elastomers. For most industrial purposes, TPU parts are delivered in raw print quality with support structures removed.

What's the lead time on TPU printing?

Standard lead time is 2-5 business days from an approved order confirmation. We offer express production in 1-2 business days if needed. Delivery is with PostNord or GLS across Denmark.

How large a part can you print in TPU?

Our FDM printers have a build volume of up to 350 × 350 × 350 mm depending on the machine. Larger parts can be split and joined afterward.

Do you offer NDAs for confidential projects?

Yes. We offer confidentiality agreements for business customers. Contact Henrik Beck directly at h.beck@makerfactory.dk to agree on terms before submitting files.

Into tabletop gaming and looking for miniatures? See our guide to Warhammer and DnD miniatures in SLA resin — the level of detail TPU can't deliver, but SLA can.